THREE-DIMENSIONAL ORTHOGONAL

WOVEN COMPOSITES INCORPORATION IN

THE AUTOMOTIVE SUPPLY CHAIN

DALIA TAYLOR, ABDEL-FATTAH M. SEYAM, NANCY B. POWELL,

MANSOUR H. MOHAMED

COLLEGE OF TEXTILES, NC STATE UNIVERSITY

RALEIGH, NC, USA

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 AUTOMOTIVE INDUSTRY DRIVES:
2

y RAW MATERIALS development

y FINANCIAL systems
y ADVANCED MATERIALS and manufacturing improvements
y SAFETY
y ENERGY
y ENVIRONMENTAL innovations
Source: America’s Auto Industry, 2006

Forecasting in 2005: 70,000,000 per year in 2010, from 55,000,000 in 2000

2008: 74,647,260 in production and 71,900,856 in sales

Source: Global Market Data Book, 2008

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 MAJOR DRIVERS OF THE AUTOMOTIVE
INDUSTRY
3
y global CONSUMERS’ expectations
y GOVERNMENT regulations: safety and environmental
issues
y development and changes in TECHNOLOGY
y COST pressures

THE NEED TO PRODUCE SAFE AND

COST EFFECTIVE LIGHTWEIGHT
VEHICLES HAS BEEN IDENTIFIED
AS CRITICAL!
Source: Veloso, 2000; Powell, 2004; Banisster, 2004

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 THE TRANSFORMATION OF THE SUV
4
75% of ENERGY consumption is
directly related to WEIGHT
SUV average millage is 21.7 MPG
SMALL CAR millage is 32 MPG
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25 % of WEIGHT reduction would
save ~13% of the total U.S. gasoline
consumption and would reduce CO2
emission by 101 million tons per year
Source: Korth, 2007
 OBJECTIVE OF THE RESEARCH
5

y REPLACE heavy METAL PARTS with LIGHTWEIGHT 3D

orthogonal woven COMPOSITES made from fiberglass
y APPROACH PERFORMANCE characteristics of VEHICLE
body with the newly created lighter and stronger
COMPOSITES
y RELATE the PERFORMANCE of the 3D woven fabric
composite to woven CONTRUCTION PARAMETERS

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 BENEFITS OF LIGHT WEIGHT COMPOSITES
6

y LIGHTER weights
y high IMPACT resistance and STRENGTH to weight ratio
y increased PRODUCTIVITY (more productive line with the
same labor and equipment)
y decreased PROCESSING TIME and higher QUALITY
(saving labor and cycle time, less assembling errors)
y COST effectiveness
y speed of RECYCLABILITY

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 BENEFITS OF 3D WOVEN COMPOSITES
7

y excellent ability to TRANSFER polymeric RESIN much

faster than equivalent thickness stack of 2-D fabrics
y HYBRIDIZATION of DIFFERENT FIBER types in the
weaving process
y ability to produce COMPLEX SHAPES (I, T, box, etc.)
y ability to CONTROL Z-FIBER VOLUME FRACTION
from extremely low (1%) to extremely high levels (60%) to
meet specified demand
y NOT susceptible to DELAMINATING

Source: www.3tex.com

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VEHICLE BODY AND CHASSIS STRUCTURE
8

Source: www.carbodydesign.com

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 3WEAVETM
9

Source: www.3tex.com

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 3D WEAVING MACHINE
10

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3D WOVEN FABRIC FORMATION
11

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MULTIPLE FILLINGS INSERTION
12

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EXAMPLES OF FORMS MADE BY 3D WEAVING
13

Source: www.3tex.com

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VACUUM-ASSISTED RESIN TRANSFER
MOLDING (VARTM) TECHNOLOGY
14

Source: Acheson et al, 2004

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VACUUM-ASSISTED RESIN TRANSFER
MOLDING (VARTM) TECHNOLOGY
15

Source: prepared by B. Schartow

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VACUUM-ASSISTED RESIN TRANSFER
MOLDING (VARTM) TECHNOLOGY
16

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 RESEARCH APPROACH
17

CONSTRUCTION PARAMETERS (variables)

y filling linear density

y filling roving linear density
y arrangements of warp and Z-yarns
y number of warp and filling layers (structure)

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 ARRANGEMENTS OF WARP AND Z-YARNS
18

1z/1w (plain weave) 1z/1w (basket weave) 1z/2w (plain weave)

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 RESEARCH APPROACH
19
The TESTED PROPERTIES include:

y Fiber content
y Heat deteriorate temperature (HDT)
y Tensile strength, modulus, and elongation
y Flexural strength and modulus
y Charpy impacts (notched and unnotched)
y Dynatup impact

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 BENEFITS TO AUTOMOTIVE APPLICATIONS
20

y STRENGTH
y LIGHTWEIGHT
y improved FUEL EFFICIENCY and C02 EMISSION
y decreased PROCESSING TIME
y increased QUALITY
y CORROSION resistance

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 INTEGRATION OF NEW TEXTILE
TECHNOLOGY
21

Changes may occur in automotive supply chain

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AUTOMOTIVE SUPPLY CHAIN STRUCTURE
22

Source: Tassey et al, 1999

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SUPPLY CHAIN NETWORKS
23

Source: Swaminathan et al, 1998

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AUTOMOTIVE DESIGN AND DEVELOPMENT
PROCESS
24

Source: Tassey et al, 1999

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CHANGES IN AUTOMOTIVE DESIGN AND
DEVELOPMENT PROCESS
25

Source: adapted from Tassey et al, 1999

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 CONCLUSIONS
26
CHANGES IN AUTOMOTIVE SUPPLY CHAIN
AFTER INCORPORATION OF 3D WOVEN
COMPOSITES:
y reduced jobs in automotive industry, but increased
in textiles; created new business
y decreased size of the automotive supply chain
y decreased time to the market
y changed position of textile industry in supplying
fibers components

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 REFERENCES
27
.
y America’s Auto Industry. (2006). Economic Contributions & Competitive
Challenges. Retrieved June 14, 2007, from
http://www.autotradecouncil.org/Images/Economic%20contribution%20conte
nt.pdf
y Banisster, M. K. (2004). Development and Application of Advanced
Textile Composites. Proceedings of the Institution of Mechanical Engineers.
Vol. 218 Part L: Journal of Materials: Design and Applications. p. 253-260.
y Korth, K. Key Issues for Suppliers: Navigating a Challenging Landscape.
OESA Cincinnati Regional Meeting. Dec. 6, 2007
y Powell, N. B. (2004). Design Driven: The Development of New Materials
in Automotive Interiors. Journal of Textile and Apparel, Technology and
Management, 3 (4). Retrieved April 2, 2007, from
http://www.tx.ncsu.edu/jtatm/volume3issue4/Articles/Powell/powell_full.pdf
y Swaminathan, J., M. Smith, S., F., Sadeh, N., M. (1998). Modeling Supply
Chain Dynamics: A Multiagent Approach. Decision Science, Vol. 29 (3),
p. 607-632.

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 REFERENCES
28

y Tassey, G., Brunnermeier, S., B., Martin, S., A. (1999). Interoperability

Cost Analysis of the U.S. Automotive Supply Chain. Research Triangle
Institute, Project Number 7007-03, North Carolina.
y Veloso, F. (2000). The Automotive Supply Chain Organization: Global
Trends and Perspectives. Working Paper. Massachusetts Institute of
Technology.
y www.3tex.com, Retrieved March 21, 2008

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