This publication describes new process chain approaches for the manufacturing of intrinsic hybrid composites for lightweight structures. The introduced process chains show a variety of different part and sample types, like insert technology for fastening of hollow hybrid shafts and profiles. Another field of research are hybrid laminates with different layers of carbon fiber reinforced plastics stacked with aluminum or steel sheets. The derived process chains base on automated fiber placement, resin transfer molding, deep drawing, rotational molding and integral tube blow molding.
Recent detailed chemical structure analyses of three demineralized kerogens from Green River oil shale samples were used to generate input parameters for the chemical percolation devolatilization (CPD) model. This model uses a lattice network to describe pyrolysis of solid hydrocarbons, such as coal and biomass. It was necessary to modify the formulation of the CPD model to account for the long aliphatic carbon chains found in oil shale, because gases formed from these long chains condense at room temperature and are counted as tar. It was initially assumed that 20% of the aliphatic material was released as light gas during formation of stable char bridges, leaving 80% of the aliphatic material to form side chains that would later be released as heavier condensable gas. With slight adjustments to the kinetic coefficients, calculations from the reformulated model agreed well with tar and light gas yields reported for these same demineralized kerogens at 10 K/min. The calculation of bridge parameters showed that the labile bridges between aromatic units were cleaved when 70% of the volatiles were released. The major release of longer side chains as heavy gas occurred in the later stages of pyrolysis. ■ INTRODUCTIONAs knowledge of the characterization of shale oil increases as a result of data derived from modern solid-state nuclear magnetic resonance (NMR), mass spectrometry, and gas chromatography, a description of oil shale pyrolysis products based on the chemical structure is possible. Many current models empirically fit the mass released during pyrolysis (e.g., ref 1) and may also empirically fit curves of individual species or tar. Reviews of simple empirical models of oil shale pyrolysis were recently performed. 2−5 Mechanistic models describe the actual chemical processes involved and may be able to describe oil shale pyrolysis over a broader range of heating conditions (heating rate, temperature, and pressure). A simple mechanism for conversion of both aromatic and aliphatic carbons to gas, oil, and coke was proposed by Burnham and Happe, 6 although kinetic coefficients and links to the chemical structure were not provided. These authors also show evidence of an aromatic growth mechanism in the residual coke. A very detailed mechanistic model [chemical structure−chemical yield modeling (CS−CYM)] based on the chemical structure of various kerogens, including oil shale, was reported by Freund et al. 7 and Walters et al. 8 Core molecular structures were developed on the basis of elemental analyses, solid-state 13 C NMR, X-ray photoelectron spectroscopy (XPS), sulfur X-ray absorption structure spectroscopy (XANES), and pyrolysis−gas chromatography (GC). The core structures were expanded stochastically to describe large macromolecules, which were then used to model pyrolysis reactions at a range of conditions, including geological conditions. The chemical percolation devolatilization (CPD) model is a mechanistic pyrolysis model originally developed by Fletcher et al. 9,10 to describe coal pyrolysis. Although n...
The increasing use of hybrid materials requires efficient manufacturing processes. With the concept of the intrinsic hybrids the shaping or forming of the part is combined with the hybridization in the same process step and thereby the same tool. Hence new tooling concepts, which realise the process requirements, are necessary. This paper describes tooling concepts and design methods for the manufacturing of intrinsic hybrid parts. Different solutions for rotational and planar parts with thermosetting or thermoplastic matrix material are presented. Additionally the integration of inserts in such tools is discussed. Finally the main challenges for the design of tools for intrinsic hybrids will be presented.
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