Browsing by Author "Elizetxea, Cristina"
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Item An Advanced Technological Lightweighted Solution for a Body in White(2016) Cischino, Elena; Di Paolo, Francesca; Mangino, Enrico; Pullini, Daniele; Elizetxea, Cristina; Maestro, Cesar; Alcalde, Estibaliz; Christiansen, Jesper deClaville; POLIMEROSFunded by the EC FP7 Program, EVolution project is using the Pininfarina Nido concept car as a baseline for its activities, with the goal to demonstrate the sustainable production of a full electric 600 kg vehicle (FEV). The project has to be finalized by the end of 2016. The existing Body in White (BiW) has been completely reviewed through a design strategy aiming to reduce the number of parts and using innovative lightweight materials and technologies. The considered Al technologies applied on high performances Al alloys provide the opportunities to obtain components with complex geometries and low thickness, merging different parts into one unique element. Besides, it is possible to process a variable thickness element with a single operation. A “green sand mold” technique allows co-casted joints among elements produced with different Al manufacturing processes. The potential cost reduction and process simplification in terms of time and assembly are promising: current state-of-the-art, based on traditional moulds, does not allow these opportunities. The BiW has been hybridized in certain areas of the underbody with a composite material of the PA family, reinforced with GF. This material has been obtained improving existing ones and developing a production process suitable for scaling to commercial requirements, throughout an advanced sheet thermoforming and 3D-injection method (CaproCAST process). Novel polypropylene nanocomposites (PNC) based on silicate and glass fiber layers demonstrate improved toughness and stiffness and have been selected for crash cross beam and side door. Polyurethane foams based on recycled polymers are explored as sustainable energy-absorbing filling in cross beam sections. Structural epoxy adhesives have been considered to join the BiW parts and welding points are reduced in number: in certain areas spot-welds have been used only to tack the parts during polymerization. In addition to the previous results, current weight of the BiW is 115 kg versus 160 kg of the baseline car. An FE-analysis on the virtual full vehicle indicates a good structural behavior, considering EU standards of crash homologation and global static and dynamic performances. The developed architecture and the integration of lightweight materials will ensure that the EU maintains its competitiveness against the Asian and United States automobile industries. This topic is focused on the results obtained on the BiW in terms of design strategies, Al and composite materials innovative technologies and joining methods.Item Assessment of nanoparticles release into the environment during drilling of carbon nanotubes/epoxy and carbon nanofibres/epoxy nanocomposites(2017-10-15) Starost, Kristof; Frijns, Evelien; Van Laer, Jo; Faisal, Nadimul; Egizabal, Ainhoa; Elizetxea, Cristina; Blazquez, Maria; Nelissen, Inge; Njuguna, James; Elizextea, Cristina; Biomateriales; POLIMEROSThe risk assessment, exposure and understanding of the release of embedded carbon nanotubes (CNTs) and carbon nanofibers (CNFs) from commercial high performance composites during machining processes are yet to be fully evaluated and quantified. In this study, CNTs and CNFs were dispersed in epoxy matrix through calendaring process to form nanocomposites. The automated drilling was carried out in a specially designed drilling chamber that allowed elimination of background noise from the measurements. Emission measurements were taken using condensed particle counter (CPC), scanning mobility particle sizer (SMPS) and DMS50 Fast Particulate Size Spectrometer. In comparison to the neat epoxy, the study results revealed that the nano-filled samples produced an increase of 102% and 227% for the EP/CNF and EP/CNT sample respectively in average particle number concentration emission. The particle mass concentration indicated that the EP/CNT and EP/CNF samples released demands a vital new perspective on CNTs and CNFs embedded within nanocomposite materials to be considered and evaluated for occupational exposure assessment. Importantly, the increased concentration observed at 10 nm aerosol particle sizes measurements strongly suggest that there are independent CNTs being released at this range.Item A Concrete and Viable Example of Multimaterial Body: The Evolution Project Main Outcomes: The Evolution Project Main Outcomes(2017) Cischino, Elena; Vuluga, Zina; Elizetxea, Cristina; Benito, Iratxe Lopez; Mangino, Enrico; de Claville Christiansen, Jesper; Sanporean, Catalina-Gabriela; Di Paolo, Francesca; Kirpluks, Mikelis; Cābulis, Pēteris; Ezeiza, Cristina Elizetxea; Cabulis, Pěteris; POLIMEROSFunded by the EC FP7 Programme, EVolution project demonstrated that it is possible to consistently reduce the vehicle weight through the wide use of new materials and process technologies, mainly by developing a multi-material Body-in-White. This paper focuses on three of the five structural body demonstrators, the main objective of the framework, strongly hybridized with aluminum and thermoplastic composite materials, specifically developed and manufactured through innovative technologies. Directing in particular the analysis on medium production volumes (> 30,000 units/year), the industrial viability is evaluated in terms of TAKT time, lightweighting costs, weight reduction and structural performances achieved.Item Development of a Novel Biobased Polyurethane Resin System for Structural Composites(2022-10-27) Echeverria-Altuna, Oihane; Ollo, Olatz; Larraza, Izaskun; Elizetxea, Cristina; Harismendy, Isabel; Eceiza, Arantxa; Tecnalia Research & Innovation; POLIMEROSPolyurethanes are gaining increasing interest for their use as structural components subjected to cyclic loads, such as leaf springs. Thermoset polyurethane (PUR) based technology offers some advantages, such as fatigue resistance, low viscosity, and fast curing. However, current PUR formulations present two major drawbacks: their petrochemical origin and high reactivity. The aim of this work was to develop a novel biobased PUR (BIO-PUR) with the required mechanical properties and processability for manufacturing structural composites by resin transfer moulding (RTM). For this purpose, a high functionality and high hydroxyl index castor-oil-based polyol was used combined with a biobased glycerol (BIO-Gly) to increase the crosslinking density and improve the final properties of the BIO-PUR. The viscosity and reactivity of the different systems were studied by means of rheology tests and differential scanning calorimetry (DSC). Thermal and mechanical properties were studied by dynamic mechanical analysis (DMA) and flexural tests. Furthermore, the RTM process of a representative part was simulated and validated through the manufacturing and testing of plates. The properties of the BIO-PUR resin systems were strongly influenced by the addition of biobased glycerol and its effect on the crosslinking density. The combination of a high functionality and hydroxyl index biobased polyol with the biobased glycerol resulted in a high-performance BIO-PUR with the required reactivity and final properties for structural applications.Item The effect of nanosilica (SiO2) and nanoalumina (Al2O3) reinforced polyester nanocomposites on aerosol nanoparticle emissions into the environment during automated drilling(2017-05) Starost, Kristof; Frijns, Evelien; Van Laer, Jo; Faisal, Nadimul; Egizabal, Ainhoa; Elizetxea, Cristina; Nelissen, Inge; Blázquez, María; Njuguna, James; Biomateriales; POLIMEROSThe aim of this study is to investigate the effect nanosilica and nanoalumina has on nanoparticle release from industrial nanocomposites due to drilling for hazard reduction whilst simultaneously obtaining the necessary mechanical performance. This study is therefore specifically designed such that all background noise is eliminated in the measurements range of 0.01 particles/cm3 and ±10% at 106 particles/cm3. The impact nano-sized SiO2 and Al2O3 reinforced polyester has on nanoparticle aerosols generated due to drilling is investigated. Real-time measurement was conducted within a specially designed controlled test chamber using a condensation particle counter (CPC) and a scanning mobility particle sizer spectrometer (SMPS). The results show that the polyester nanocomposite samples displayed statistically significant differences and an increase in nanoparticle number concentration by up to 228% compared to virgin polyester. It is shown that the nanofillers adhered to the polyester matrix showing a higher concentration of larger particles released (between 20 – 100 nm). The increase in nanoparticle reinforcement weight concentration and resulting nanoparticle release vary considerably between the nanosilica and nanoalumina samples due to the nanofillers presence. This study indicates a future opportunity to safer by design strategy that reduces number of particles released concentration and sizes without compromising desired mechanical properties for engineered polymers and composites.Item Environmental Particle Emissions due to Automated Drilling of Polypropylene Composites and Nanocomposites Reinforced with Talc, Montmorillonite and Wollastonite(2017-05-11) Starost, K.; Frijns, E.; Laer, J.V.; Faisal, N.; Egizabal, A.; Elizetxea, Cristina; Nelissen, I.; Blazquez, M.; Njuguna, J.; Elizextea, C.; Biomateriales; POLIMEROSIn this study, the effect on nanoparticle emissions due to drilling on Polypropylene (PP) reinforced with 20% talc, 5% montmorillonite (MMT) and 5% Wollastonite (WO) is investigated. The study is the first to explore the nanoparticle release from WO and talc reinforced composites and compares the results to previously researched MMT. With 5% WO, equivalent tensile properties with a 10 % weight reduction were obtained relative to the reference 20% talc sample. The materials were fabricated through injection moulding. The nanorelease studies were undertaken using the controlled drilling methodology for nanoparticle exposure assessment developed within the European Commission funded SIRENA Life 11 ENV/ES/506 project. Measurements were taken using CPC and DMS50 equipment for real-time characterization and measurements. The particle number concentration (of particles <1000nm) and particle size distribution (4.87nm - 562.34nm) of the particles emitted during drilling were evaluated to investigate the effect of the silicate fillers on the particles released. The nano-filled samples exhibited a 33% decrease (MMT sample) or a 30% increase (WO sample) on the average particle number concentration released in comparison to the neat polypropylene sample. The size distribution data displayed a substantial percentage of the particles released from the PP, PP/WO and PP/MMT samples to be between 5-20nm, whereas the PP/talc sample emitted larger particle diameters.Item Evolution FP7 funded project: body structure design strategies using new composite and aluminium materials and enabled technologies(InderScience, 2018-04-20) Mangino, Enrico; Alcalde, Estibaliz; Maestro, César; Di Paolo, Francesca; DeClaville Christiansen, Jesper; Sanporean, Catalina Gabriela; Deverill, John P.; Cischino, Elena; Elizetxea, Cristina; Lopez, Iratxe; Vuluga, Zina; Kirpluks, Mikelis; Cabulis, PeterisBased on Pininfarina Nido EV concept, EVolution aims to reduce the vehicle weight through new materials and process technologies, focused on five demonstrators: underbody, front crossbeam, mechanical subframe, shotgun system and door. This paper refers to body structure design strategies using new composite, Al materials and enabled technologies, focusing in particular on demonstrators design and manufacturing. The new front crossbeam geometry of the front shell is adapted starting from the Nanotough design, while the rear shell is specific for EVolution. The subframe demonstrator is redesigned to fulfil mechanical requirements of the part and manufacturing feasibility either. The EVolution door concept consists of two semistructural composite skins including a structural Al frame. The underbody is conceived through an integrated approach, optimising each element for its function. The shotgun component is designed to link parts obtained with different manufacturing technologies and several aluminium alloys in one single component: the structural node demonstrator.Item Morphological and Tribological Properties of PMMA/Halloysite Nanocomposites(2018-07-25) Vuluga, Zina; Corobea, Mihai; Elizetxea, Cristina; Ordonez, Mario; Ghiurea, Marius; Raditoiu, Valentin; Nicolae, Cristian; Florea, Dorel; Iorga, Michaela; Somoghi, Raluca; Trica, Bogdan; POLIMEROSFrom an environmental and cost-effective perspective, a number of research challenges can be found for electronics, household, but especially in the automotive polymer parts industry. Reducing synthesis steps, parts coating and painting, or other solvent-assisted processes, have been identified as major constrains for the existing technologies. Therefore, simple polymer processing routes (mixing, extrusion, injection moulding) were used for obtaining PMMA/HNT nanocomposites. By these techniques, an automotive-grade polymethylmethacrylate (PMMA) was modified with halloysite nanotubes (HNT) and an eco-friendly additive N,N′-ethylenebis(stearamide) (EBS) to improve nanomechanical properties involved in scratch resistance, mechanical properties (balance between tensile strength and impact resistance) without diminishing other properties. The relationship between morphological/structural (XRD, TEM, FTIR) and tribological (friction) properties of PMMA nanocomposites were investigated. A synergistic effect was found between HNT and EBS in the PMMA matrix. The synergy was attained by the phase distribution resulted from the selective interaction between partners and favourable processing conditions. Modification of HNT with EBS improved the dispersion of nanoparticles in the polymer matrix by increasing their interfacial compatibility through hydrogen bonding established by amide groups with aluminol groups. The increased interfacial adhesion further improved the nanocomposite scratch resistance. The PMMA/HNT-EBS nanocomposite had a lower coefficient of friction and lower scratch penetration depth than PMMA/HNT nanocomposite.Item Nucleation and Crystallization of PA6 Composites Prepared by T-RTM: Effects of Carbon and Glass Fiber Loading: Effects of carbon and glass fiber loading(2019-10-01) Zaldua, N.; Maiz, J.; de la Calle, A.; García-Arrieta, S.; Elizetxea, Cristina; Harismendy, I.; Tercjak, A.; Müller, A.J.; POLIMEROSThermoplastic resin transfer molding (T-RTM) is attracting much attention due to the need for recyclable alternatives to thermoset materials. In this work, we have prepared polyamide-6 (PA6) and PA6/fiber composites by T-RTM of caprolactam. Glass and carbon fibers were employed in a fixed amount of 60 and 47 wt.%, respectively. Neat PA6 and PA6 matrices (of PA6-GF and PA6-CF) of approximately 200 kg/mol were obtained with conversion ratios exceeding 95%. Both carbon fibers (CF) and glass fibers (GF) were able to nucleate PA6, with efficiencies of 44% and 26%, respectively. The α crystal polymorph of PA6 was present in all samples. The lamellar spacing, lamellar thickness and crystallinity degree did not show significant variations in the samples with or without fibers as result of the slow cooling process applied during T-RTM. The overall isothermal crystallization rate decreased in the order: PA6-CF > PA6-GF > neat PA6, as a consequence of the different nucleation efficiencies. The overall crystallization kinetics data were successfully described by the Avrami equation. The lamellar stack morphology observed by atomic force microscopy (AFM) is consistent with 2D superstructural aggregates (n = 2) for all samples. Finally, the reinforcement effect of fibers was larger than one order of magnitude in the values of elastic modulus and tensile strength.