Description

DTC Approval Certification Materialgutachten (GFK) Glass Fiber Reinforced Plastic

Technical Expertise of Material: DTC Approval Certification Materialgutachten (GFK) Glass Fiber Reinforced Plastic

This technical expertise aims to deliver a comprehensive evaluation of automotive components manufactured from composite materials, specifically focusing on GFK (glass fiber reinforced plastic) and CFK (carbon fiber reinforced plastic), as well as ABS parts. These components undergo rigorous testing following the protocols set by DTC or FAKT GmbH. The objective is to ensure compliance with precise technical specifications, verify optimal functional performance, and maintain structural integrity in extreme automotive conditions. The evaluation utilizes stringent testing methodologies and advanced performance criteria to guarantee the quality and reliability of the components before installation or competitive use.

GFK and Composites: In-Depth Technical Analysis

Composite Materials: GFK vs. CFK

• GFK (Glass Fiber Reinforced Plastic): GFK comprises glass fibers embedded within a resin matrix, typically polyester or vinyl ester. Known for its cost-effectiveness and good mechanical properties, GFK is generally less strong and rigid compared to CFK. It is preferred for its resistance to corrosion and flexibility, particularly where a favorable cost-performance ratio is more critical than extreme lightweight properties.Analysis of Glass Fiber Properties: Glass fibers are evaluated for strength and flexibility, although their modulus of elasticity is lower compared to carbon fibers. Fiber orientation is optimized to enhance tensile strength and impact resistance. Tests include tensile strength measurements, impact tests, and deformation analyses under load.
• CFK (Carbon Fiber Reinforced Plastic): CFK consists of carbon fibers embedded in a thermosetting resin matrix, usually epoxy or phenolic. Carbon fibers provide exceptional tensile strength and high stiffness along the fiber direction due to their unidirectional alignment. The thermosetting resins form a rigid matrix that ensures dimensional stability under high temperatures and significant mechanical loads.Analysis of Carbon Fiber Properties: Carbon fibers are assessed for their high modulus of elasticity and superior specific strength. They are layered in various orientations to enhance mechanical properties. Testing involves measuring tensile modulus, bending tests, and impact resistance evaluations.

Detailed Evaluation of Components: DTC Approval Certification Materialgutachten (GFK) Glass Fiber Reinforced Plastic

1. Front Spoilers / Lips / Front Bumpers:
   • Material Analysis: Comprehensive examination of the chemical composition of GFK, CFK, and ABS, focusing on reinforcement concentration, additive types, and resin-fiber compatibility. Methods include infrared spectroscopy, chromatography, and microscopy.
   • Impact Resistance Testing: Dynamic tests to simulate real-world impacts, such as drop tests, projectile impacts, and plastic deformation. Force and deformation sensors are used to measure performance.
   • Aerodynamic Analysis: Evaluation of aerodynamic effects using wind tunnels and CFD (Computational Fluid Dynamics) simulations. Tests measure drag, lift, and lateral forces using pressure sensors and flow visualization techniques.
2. Side Skirts:
   • Structural Integrity Examination: Assessment of mechanical properties such as tensile strength, flexibility, and fatigue resistance through bending tests and cyclic fatigue tests. Includes analysis of material behavior under static and dynamic loads.
   • Environmental Effects Assessment: Accelerated aging tests to determine material durability under temperature fluctuations, humidity, and UV exposure. Samples are subjected to extreme thermal cycles and corrosive environments.
3. Rear Deflectors / Rear Bumpers / Diffusers:
   • Compliance Analysis: Verification of dimensions and compatibility with vehicle specifications using 3D measurement methods and digital twin technology. Ensures precise fitting and adherence to safety and performance standards.
   • Air Flow Management Testing: Assessment of aerodynamic performance through CFD simulations and wind tunnel tests. Evaluates turbulence management, downforce generation, and pressure interactions.
4. Roof Spoilers / Rear Trunk Spoilers / Ducktail:
   • Aerodynamic Performance Testing: Detailed studies of aerodynamic drag and downforce using advanced CFD simulations and wind tunnel tests. Measures impacts on vehicle stability, lift forces, and roll moments at high speeds.
   • Attachment Analysis: Inspection of attachment systems to verify their ability to withstand dynamic forces. Includes static and dynamic load tests, as well as vibration simulations to evaluate connection reliability and safety.
5. Fender Extensions / Wheel Arch Widenings / Overfenders:
   • Fit Evaluation: Precise assessment of the fit of extensions relative to the vehicle body using high-precision measurement tools. Ensures proper integration and avoids interference. Tests include tolerance analysis and mounting simulations.
   • Element Resistance Testing: Analysis of resistance to stone chipping, corrosion, and severe climatic conditions. Materials undergo abrasion tests, salt spray corrosion tests, and exposure to extreme weather conditions.

Legal CH and Regulatory Framework: DTC Approval Certification Materialgutachten (GFK) Glass Fiber Reinforced Plastic

• Swiss Legislation and Applicable Standards:
  • Road Vehicles Ordinance (OVR): Under Article 42 of the Federal Roads Act (LRN), the OVR establishes technical requirements for vehicle safety. Components must meet these requirements to ensure safety and performance.
  • Road Traffic Act (LCR): Article 13 mandates that vehicles and their components comply with safety standards and directives set by the Federal Roads Office (OFROU) and other relevant authorities.
  • Ordinance on Technical Requirements for Vehicles (OETV): Regulates specific technical requirements for automotive parts, ensuring alignment with safety standards and environmental regulations.
  • Federal Court Rulings: Decisions by the Swiss Federal Court regarding vehicle safety standards and part certifications are essential for ensuring legal and technical compliance. Relevant case law must be considered to align with established precedents.
• Recognized Certification Centers:
  • DTC (DTC Testing Center): Accredited by OFROU for the performance and safety testing of automotive components, including impact resistance and aerodynamic compliance.
  • FAKT GmbH : Accredited by OFROU Specializes in performance and durability testing of composite parts, including mechanical evaluations and aerodynamic simulations.
  • ABE (Automotive Engineering Association): Certified body for automotive part certification, conducting rigorous tests on performance and adherence to technical standards.
  • TÜV (Technischer Überwachungsverein): Renowned German organization for part certification and compliance testing, including composites and safety components.

Exclusions: DTC Approval Certification Materialgutachten (GFK) Glass Fiber Reinforced Plastic

This expertise does not cover engine hoods, which require specialized evaluations concerning thermal properties, impact resistance, and structural integrity. Specific analyses would involve heat resistance tests, deformation under thermal loads, and simulations of impact conditions to meet safety standards and thermal performance requirements.