In this interview Dr. Sivakumara Krishnamoorthy, Manager of New Applications at Evonik Performance Foams talks to AZoM about their newest technology, PulPress™ for Automotive and Aerospace industries.
Sivakumara博士解释了Pulpress™与以前生产复杂复合组件的方法相比的好处和进步。
By using a core material that can withstand high temperatures and pressurised environments, Evonik’s PulPress™ Technology employs the latest in innovative high performance materials and technology to produce composite components cost-effectively.
您能简要概述有关Evonik最近推出的新Pulpress™技术吗？
PulPress™ technology is a unique new processing method developed by Evonik that enables manufacturers to produce complex 3-dimensional, molded composite parts in high volumes.
The first components made using PulPress™ technology are already making their way into series production this year and cost savings are up to 60 percent over established methods traditionally used in the past.
创建Pulpress™技术的激励措施是什么？
我们的移动性领域的客户越来越多地寻找轻量级的解决方案，并开始越来越依赖复合材料作为减少燃料消耗的一种手段，并且2emissions. Until now, composites were primarily used in high-end segments and luxury-class automobiles because established composite manufacturing technologies can be expensive and complex.
随着Pulpress™技术的引入，制造商现在有了一个新的选项，可为他们提供高效且易于使用的过程。制定用高性能复合材料代替金属组件的设计决策不再具有高价标签。
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其他技术不提供的Qualpress™技术提供了什么？
The PulPress™ method makes it possible to produce a high-quality complex composite component quickly, economically and with no waste. This simply isn’t possible with standard processes used in the past.
例如，树脂转移成型（RTM）涉及许多中间步骤，相对较长的周期时间并产生大量废料。因此，如果使用RTM，零件的成本很高。
Another standard process called Pultrusion is fast, continuous and economic, but the freedom of design is very limited – so only simple parts are possible. However, PulPress™ technology uniquely combines two traditional production techniques: compression molding and pultrusion. The result is an efficient solution that creates complex composite parts that are affordable.
Pulpress™技术是否需要组件核心的特定材料？
Critical to success in implementing PulPress™ technology is using a core material that can withstand the high temperature and pressure environment.
Evonik的高性能Rohacell®Polymethacrylimide（PMI）泡沫是理想的材料解决方案。这种极端的处理环境是Rohacell®的性能要比任何其他可用的结构泡沫都更好，并且很容易被热成型。
What are the technical advantages and manufacturing benefits of PulPress™?
特别令人印象深刻的方面包括设计的灵活性，效率和成品零件的卓越机械性能。复合零件比传统的钢结构轻约75％，但它们提供了相同的强大支持。从机械上讲，这些低密度组件表现出出色的承载能力，并且在撞击过程中具有出色的崩溃行为。
此外，Pulpress™工艺几乎不会浪费核心材料，纤维或树脂。这显然对制造商具有生态和经济优势。
为了额外的优势，该方法允许在组件之间轻松整合聚合物或金属插入物，以进行机械负载传输，从而消除了后处理步骤和成本。
您能解释Pulpress™的经济利益吗？
使用Pulpress™技术制作复合零件时，三个主要因素会大大降低成本。首先，该方法消除了材料废物和NC缓冲的几个步骤，用于塑造复杂的泡沫几何形状。
此外，在构建复合零件时，原始纤维和树脂在100％使用。其次，由于Rohacell®在高温和压力下快速处理的能力，周期时间大大提高。单个紧凑型生产线的输出每小时超过30个组件。
Third, the simplicity of the technology eliminates several intermediate processing steps used in standard methods including preforming, draping, binder-activation, lay-up, etc.
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kvsan/shutterstock.com
How will the automotive industry benefit from Evonik’s new PulPress™ Technology?
在汽车行业中，复杂的复合配置文件可以用作汽车车身设计中的轻质结构组件，也可以用作保险杠，冲击梁，支撑杆，车顶架和车顶弓的附加零件。
Pulpress™还可以在保持相同的结构性能的同时，在车身中实现较低的“包装空间”。所需空间的这种减少导致了更多的设计自由，以塑造汽车车身的新的有吸引力的外观。
即使是刚度条和轴等底盘组件，也可以使用Pulpress™方法制成。Pulpress™技术的好处已经赢得了汽车行业中的许多Evonik客户的胜利。
Does PulPress™ offer any advantages to the aviation industry?
Pulpress™技术的技术和经济利益当然适用于航空业的组件制造商。高质量的Pulpress™零件的非常狭窄的尺寸和机械公差。
因此，可以想象可以成功地将飞机组件构造应用于生产不变零件的成本效益方法。即使是具有常见“基础”几何形状的可变零件，也可以使用模块化工具在经济上产生。
PulPress™ opens up new opportunities for structural solutions, where the move from metals to CFRP have been until now cost-prohibitive. Low cost processing of high performance materials could be a key enabler for mid- to long-term technology targets.
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Stockphoto mania/shutterstock。com
Why should a company use Evonik’s PulPress™ Technology?
使用三明治复合材料制造超轻质，高性能零件是一种良好的结构原理。Pulpress™流程可以通过快速，经济和资源有效的复合组件生产将技术从高端细分市场转移到大规模生产。
This brings new opportunities for component manufacturers as well as aircraft and automotive OEM’s in their quest to meet future demands in lightweight construction.
Evonik提供了对Pulpress™技术的访问，作为有效的零件生产解决方案。虽然我们不出售实际的成品零件，但我们可以提供Rohacell®泡沫核心进行投入，并与客户紧密合作，以提供技术工程支持，以在其生产中实施Pulpress™技术。
我们的读者可以在哪里了解更多？
要了解有关Evonik的Pulpress™技术的更多信息，请致电+49（6151）18-1005与您所在地区的Rohacell®代表联系，或通过电子邮件发送Sivakumara.krishn[email protected]
关于Sivakumara“ Siva” Krishnamoorthy
Sivakumara Krishnamoorthy博士是Evonik资源效率部门的Performance Foams业务部门新应用程序的经理，并负责Pulpress™技术。他的职业生涯始于2013年，是一名高级项目经理，负责Evonik Creavis GmbH项目房屋复合材料中的新产品和技术。2016年，他接管了他目前在Evonik绩效泡沫业务的营销和销售部门中的角色。
Siva completed his Bachelor degree in mechanical engineering from the College of Engineering, Guindy, India in 2002 and then earned his Master of Science in computational mechanics of materials and structures from the University of Stuttgart, Germany in 2004. He later received his doctorate in engineering sciences from the RWTH Aachen University, Germany in 2010. Subsequently, he worked as a project manager & research associate at the German Aerospace Center in Stuttgart dealing with the development of lightweight vehicle structures.
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