Awaiting Public Project Summary

Formax UK Ltd and Loughborough University are collaborating to develop a novel fibre treatment process, for the purposes of improving the performance of existing composites used throughout the aerospace sector, with a view to reduction in vehicle mass and emissions. This has formed as an outcome of prior research conducted between the two organisations. The aim of the project is to conduct a feasibility study into potential applications and identify suitable route to market.

GKN through its expertise in composites and vehicle structures (Autostructures) sees a potential to offer their Automotive OEM customers vehicle structures incorporating composite lightweight components.Legislation is driving lower CO2 targets, historically achieved through powertrain efficiencies however the industry is in agreement the technological focus will have to shift to light weighting to achieve ever tighter limits. GKN knows that adoption of new technology will only happen once the business case supports it, this will require an efficient supply chain and lean manufacturing processes capable of meeting the customers’ requirements for cost, volume and quality.The focus for this project will centre upon GKN working to establish a UK based, light weight supply chain supporting this high value and “sticky” technology, building a consortium of industry experts concentrating on technologies in the areas of manufacturing processes, joining technology and non-destructive testing, which will be essential to meet the customer needs and provide lightweight structures in automotive volumes.

Manufacturing lightweight vehicles from carbon fibre reinforced composites significantly lowers fuel consumption and therefore reduces CO2 and other emissions. Currently, the high cost of carbon fibre composites is a barrier to the inclusion of these materials in mass-produced vehicles. This project aims to develop a low cost composite manufacturing technique that will make composites a feasible alternative to metals in family cars and other road vehicles. The innovative manufacturing route developed in this project aims to reduce cost through two factors: 1) eliminating waste during composite production; 2) using cheaper starting materials without compromising the properties of the finished components. The consortium for this project includes industrial and academic partners. Combined they have a wealth of experience in developing composite materials and together have the ability to create an effective solution to reducing harmful vehicle emissions.

BRAKE-THRU is a new type of automotive braking system for future Low Carbon Vehicle’s. The aim is to provide this emerging industry with a lightweight and cost-effective alternative to grey cast iron rotors - the traditional material of choice for over 50 years. In future LCV’s, weight will be critical, where currently, car makers still have to fit cast iron rotors to their vehicles as no economically viable lightweight alternative exists. The weight burden does not merely extend to the rotors themselves [40kg for family saloon], it also forms part of the vehicle un-sprung weight. Unsprung weight reduction is highly beneficial for improving fuel economy and a key enabler that then allows the onward safe reduction of the sprung weight in modern vehicles, where any reduction has a positive effect on acceleration and cornering and also improves the ability of the suspension in maintaining tyre grip. The fuel savings from unsprung weight reduction are far more substantial than achieved by equivalent reductions to the car body. BRAKE-THRU is a 6 partner 2yr initiative, bringing together knowhow from the world of automotive friction materials, car brake system design, and the composites industry.

With the ever more stringent requirements on improved fuel efficiency and CO2 emission reduction for road vehicles, a key enabling technology is the use of advanced composite materials to significantly reduce the mass of vehicles on the road. Life cycle analysis has shown that approximately 15% of total CO2 emissions results from material and parts production, assembly and disposal. The remaining 85% of the CO2 is emitted during operation and driving. The lighter the vehicle is, the less fuel is burnt and the lower are the CO2 emissions. A 10% reduction in vehicle mass improves fuel consumption by 7%, and every litre of fuel saved reduces CO2 emissions by 2.6kg. Advanced carbon fibre composite materials have higher strength to weight ratios, better chemical and heat resistance and greater design flexibility when compared to conventional automotive construction materials. A consortium, led by an automotive OEM, with partners including a material supplier, high value manufacturing catapult centres and an academic institution, aim to develop technologies that will significantly reduce the cost of utilising these advanced materials in vehicle structures, a traditional barrier to date. Through a combination of reduced material wastage and automated pre-form manufacture, these technologies will have a significant impact on the cost of resin transfer moulded composite components. Not only will they be of benefit to the automotive industry, but also to other industrial sectors such as wind energy, sporting goods and aerospace.

To develop a comprehensive material characterisation capability and advanced simulation methodology for composites.

Awaiting Public Summary

Awaiting Public Summary