Description
DTC Carbon Approval Certification Materialgutachten (CFK Carbon)
Technical Expertise of Material:
The purpose of this expertise is to conduct a thorough evaluation of components made from composite materials, particularly CFK (carbon fiber reinforced plastic) and GFK (glass fiber reinforced plastic), as well as ABS parts, subjected to testing protocols by DTC or FAKT GmbH. This analysis aims to ensure compliance with stringent technical specifications, optimal functional performance, and structural integrity in extreme automotive environments. The expertise ensures the quality and reliability of the parts before installation or competitive use, relying on rigorous testing methodologies and advanced performance criteria.
Carbon and Composites: In-Depth Technical Analysis
Composite Materials: CFK vs. GFK:
- CFK (Carbon Fiber Reinforced Polymer): CFK is a composite material where carbon fibers are embedded in a thermosetting resin matrix, typically epoxy or phenolic. Carbon fibers, characterized by their unidirectional alignment, impart exceptional tensile strength and remarkable stiffness along the fiber direction. Thermosetting resins, once cured, form a rigid matrix that prevents thermal deformation, ensuring dimensional stability at high temperatures and under heavy mechanical loads.
- Analysis of Carbon Fiber Properties: Carbon fibers have a high modulus of elasticity and superior specific strength compared to other fibers. They are often laid in overlapping layers in various directions to create multidirectional reinforcement, optimizing the mechanical properties of the composite. Tests include measurements of tensile modulus, bending tests, and impact resistance evaluations.
- GFK (Glass Fiber Reinforced Polymer): GFK utilizes glass fibers as reinforcement within a resin matrix, typically polyester or vinylester. GFK is valued for its lower cost compared to CFK and its good mechanical performance, although its properties are generally inferior in terms of specific strength and rigidity. GFK is often used in applications where high corrosion resistance and flexibility are required, but where cost-performance ratio is more critical than extreme lightness.
- Analysis of Glass Fiber Properties: Glass fibers offer acceptable strength and good flexibility, although their modulus of elasticity is lower than that of carbon fibers. The fibers are typically oriented to maximize tensile strength and impact resilience. Tests include tensile strength analysis, impact tests, and deformation under load evaluations.
Detailed Evaluation of Components:
1 Front Spoilers / Lips / Front Bumpers: DTC Carbon Approval Certification Materialgutachten (CFK Carbon)
- Material Analysis: In-depth assessment of the chemical composition of composite materials (CFK, GFK) and ABS, examining the concentration of reinforcements, types of additives used to enhance toughness and flexibility, and compatibility between fibers and resin. Material characterization is performed using infrared spectroscopy, chromatography, and microscopic analyses.
- Impact Resistance Testing: Conducting dynamic impact resistance tests to simulate real-world usage conditions, including drop tests, projectile impacts, and plastic deformation. Samples are subjected to simulated shock loads and measured using force and deformation sensors.
- Aerodynamic Analysis: Detailed study of the effects of spoilers on air flow dynamics using wind tunnels and CFD (Computational Fluid Dynamics) simulations. Tests measure drag, lift, and lateral forces, employing pressure sensors and flow visualizations to optimize aerodynamic performance.
2 Side Skirts: DTC Carbon Approval Certification Materialgutachten (CFK Carbon)
- Structural Integrity Examination: Inspection of the mechanical properties of materials, including tensile strength, flexibility, and fatigue resistance through bending tests and cyclic fatigue tests. Materials are analyzed for their behavior under static and dynamic loads.
- Environmental Effects Assessment: Accelerated aging tests to evaluate material durability against temperature variations, humidity, and UV exposure. Samples undergo extreme thermal cycles and corrosive environments to simulate severe climatic conditions.
3 Rear Deflectors / Rear Bumpers / Diffusers: DTC Carbon Approval Certification Materialgutachten (CFK Carbon)
- Compliance Analysis: Detailed verification of dimensions and compatibility of parts with vehicle specifications, using three-dimensional measurement methods and digital twins to ensure precise fitting and adherence to safety and performance standards.
- Air Flow Management Testing: Simulation and analysis of aerodynamic flows to evaluate the effectiveness of deflectors and diffusers. Tests include CFD simulations and wind tunnel evaluations to assess turbulence management, downforce, and pressure contacts.
4 Roof Spoilers / Rear Trunk Spoilers / Ducktail: DTC Carbon Approval Certification Materialgutachten (CFK Carbon)
- Aerodynamic Performance Testing: In-depth studies of aerodynamic drag and downforce generation using advanced CFD simulations and wind tunnel tests. Tests measure the impact of spoilers on vehicle stability at high speeds, as well as lift forces and roll moments.
- Attachment Analysis: Inspection of attachment systems to verify their ability to withstand dynamic forces, including static and dynamic load tests, as well as vibration simulations to assess the reliability and safety of connections under extreme conditions.
5 Fender Extensions / Wheel Arch Widenings / Overfenders: DTC Carbon Approval Certification Materialgutachten (CFK Carbon)
- Fit Evaluation: Precise verification of the fit of extensions relative to the vehicle body, using high-precision measurement tools to avoid interference and ensure perfect integration. Tests include tolerance analysis and mounting simulations.
- Element Resistance Testing: Analysis of the resistance of extensions to stone chipping, corrosion, and severe climatic conditions. Materials are subjected to abrasion tests, salt spray corrosion tests, and exposure to extreme weather conditions.
Legal CH and Regulatory Framework:
Swiss Legislation and Applicable Standards:
- Road Vehicles Ordinance (OVR): Governed by Article 42 of the Federal Roads Act (LRN), this ordinance establishes technical requirements related to vehicle safety. Components must comply with safety and performance requirements stipulated by the OVR.
- Road Traffic Act (LCR): In accordance with Article 13, vehicles and their parts must meet safety standards and directives set by the Federal Roads Office (OFROU) and other competent authorities.
- Ordinance on Technical Requirements for Vehicles (OETV): Regulates specific technical requirements for automotive parts, aligning with safety standards and environmental regulations.
- Federal Court Rulings: Relevant decisions by the Swiss Federal Court regarding vehicle safety standards and part certifications must be considered to ensure legal and technical compliance of components.
Recognized Certification Centers:
- DTC (DTC Testing Center): Accredited by OFROU for performance and safety testing of automotive components, including impact resistance and aerodynamic compliance.
- FAKT (Forschungsgesellschaft Automobiltechnik e.V.): Recognized expertise center for performance and durability testing of composite parts, specializing in mechanical evaluations and aerodynamic simulations.
- ABE (Automotive Engineering Association): Certified body for automotive part certification, with rigorous tests on performance and compliance with technical standards.
- TÜV (Technischer Überwachungsverein): Renowned German organization for part certification and compliance testing, including composites and safety components.
Exclusions: DTC Carbon Approval Certification Materialgutachten (CFK Carbon)
This expertise does not cover engine hoods. Engine hoods require specific evaluation regarding thermal properties, impact resistance, and structural integrity according to safety standards and thermal performance requirements. Specific analyses include heat resistance tests, deformation under thermal load, and impact condition simulations.
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