Carbon fibre reinforced polymer (CFRPs) are composite materials widely used in the automotive industry because of their light-weight, high specific stiffness and high impact energy absorption. However, due to the high demand of CFRPs, their end-of-life have become an issue. Therefore, RYMYC s.r.l. proposes an alternative to landfilling; weaving scraps are treated and reintroduced in the market as a nonwoven called RYMFELT. Thanks to C.I.T. s.r.l. the material is converted into a prepreg with EY440 as a resin. The aim of this thesis work is to introduce RYMFELT in the automotive sector in order to produce cheaper and more environmentally friendly components. In collaboration with Dallara Automobili S.p.A. it was possible to test the drapability and consistency of RYMFELT in autoclave and compression moulding producing an automotive bodypanel and a louver for Nascar competition. Thanks to Faber Composites s.r.l., the nonwoven was also used to produce an Euroformula engine cover in resin transfer moulding. RYMFELT was also mechanically tested through three-point bending and compared with previous thesis and commercially available materials. Finally, the engine cover was statically tested and compared with the current Dallara solution made in glass fibre. In order to ease the lamination of the material and guarantee repeatability of the production, further studies might focus on the process stability of the felt itself and on new racing applications.
I materiali compositi in fibra di carbonio (CFRPs) sono ampiamente utilizzati nel settore autmobilistico in quanto sistemi leggeri, molto rigidi e con alto assorbimento di energia. La grande richiesta e utilizzo di CFRPs ha intrinseco il problema del loro smaltimento. Per questo motivo RYMYC s.r.l. propone di recuperare gli scarti tessili e reintrodurli nel mercato sottoforma di tessuto non tessuto (TNT) chiamato RYMFELT. Grazie a C.I.T. s.r.l. questo feltro viene impregnato con resina EY440. Lo scopo di questa tesi sarà di introdurre RYMFELT nel settore automobilisto producendo componenti di carrozzeria più economici ed ecosostenibili. In collaborazione con Dallara Automobili S.p.A. è stato possibile testare la laminazione di RYMFELT in autoclave e in pressa, stampando un pannello di carrozzeria e una presa ad aria per la competizione Nascar. Inoltre, grazie a Faber Composites s.r.l., è stato realizzato un cupolino per la competizione Euroformula. Il TNT è stato testato meccanicamente mediante flessione a tre punti e i risultati sono stati confrontati con le tesi precedenti e altri materiali disponibili in commercio. Per concludere, è stata studiata la rigidezza del cupolino e confrontato con la soluzione attuale in fibra di vetro. Per semplificare la laminazione del materiale e garantire la ripetibilità di processo, gli studi futuri potrebbero focalizzarsi sulla stabilità di produzione del feltro ed utilizzarlo all'interno di altri componenti.
Automotive applications for recycled carbon fibre nonwoven
Sebastiani, Micaela
2022/2023
Abstract
Carbon fibre reinforced polymer (CFRPs) are composite materials widely used in the automotive industry because of their light-weight, high specific stiffness and high impact energy absorption. However, due to the high demand of CFRPs, their end-of-life have become an issue. Therefore, RYMYC s.r.l. proposes an alternative to landfilling; weaving scraps are treated and reintroduced in the market as a nonwoven called RYMFELT. Thanks to C.I.T. s.r.l. the material is converted into a prepreg with EY440 as a resin. The aim of this thesis work is to introduce RYMFELT in the automotive sector in order to produce cheaper and more environmentally friendly components. In collaboration with Dallara Automobili S.p.A. it was possible to test the drapability and consistency of RYMFELT in autoclave and compression moulding producing an automotive bodypanel and a louver for Nascar competition. Thanks to Faber Composites s.r.l., the nonwoven was also used to produce an Euroformula engine cover in resin transfer moulding. RYMFELT was also mechanically tested through three-point bending and compared with previous thesis and commercially available materials. Finally, the engine cover was statically tested and compared with the current Dallara solution made in glass fibre. In order to ease the lamination of the material and guarantee repeatability of the production, further studies might focus on the process stability of the felt itself and on new racing applications.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/214870