Collaborative optimization of hot pressing and laying of CFRP steel hybrid load-bearing wheels: reducing weight by 15.33% while maintaining the wear resistance of the steel ring

Research Background and Objectives

Thermoplastic CFRP composites have potential in the field of lightweight rail vehicle wheels due to their high specific strength and fatigue resistance. However, improper molding parameters and layer design can lead to resin defects, and the PEEK matrix itself has insufficient wear resistance. The research team carried out collaborative optimization of molding process parameters and fiber layer configuration for CFRP steel hybrid load-bearing wheels prepared by fixed low-pressure hot pressing, with the goal of improving wear resistance while enhancing load-bearing performance.

Key experimental design and data

Three layered CFRP steel hybrid wheels were prepared using precision hot pressing, and the effects of curing temperature, insulation time, and layup direction on bending behavior were evaluated through single factor experiments.

. The main findings include:

• The laying direction has the most significant effect: The bending strength of the laying layer reaches 1225 MPa at [0 °] 20s, which is 28.3% higher than that of the 90 ° configuration.
• 45 ° layupProvides optimal dimensional stability and fracture toughness, with minimal performance degradation in complex flange areas.
• Optimize process parameters: Heat up from 3 ° C/min to 370 ° C, hold for 30 minutes, and demold below 60 ° C, balancing performance and efficiency.

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• Steel ring integration: After introducing steel wear-resistant rings, the hybrid wheel has both high load-bearing capacity and enhanced wear resistance, achieving a weight reduction of 15.33% compared to aluminum alloy wheels.

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The study also pointed out that phosphating surface modification can significantly strengthen the interface bonding between steel and composite materials, and the layer direction is the core factor determining the bending performance of the component.

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Significance for polymer additives and rubber tire industry

Although this study focuses on thermoplastic CFRP load-bearing wheels, its systematic optimization ideas for interface bonding, wear resistance, and lightweight have transferable reference value for the fields of tires and rubber products.

. In rubber formulations, the dispersion and interfacial interactions of reinforcing fillers (such as white carbon black) directly affect wear resistance and dynamic performance; The design of the vulcanization system determines the durability of the cross-linked network and the product; Antioxidants and antioxidants are related to the aging behavior of rubber components under long-term load and thermal history. The collaborative optimization method of “process parameters structure performance” in research is consistent with the logic of balancing load-bearing, wear resistance, and lightweight in tire rubber mixing, vulcanization processes, and tire structural design. It is particularly noteworthy that the interface strengthening strategy of steel composite materials can provide ideas for the interface treatment of rubber metal composite products (such as tire retreading), and the temperature and time window control in hot pressing molding also echoes the fine control of rubber vulcanization process.

Limitations and Issues to be Verified

This study focuses on specific CFRP steel hybrid wheel configurations and PEEK matrices, and caution should be exercised when directly extrapolating conclusions to rubber tire systems.

. The specific formula of rubber additives or actual tire working condition testing is not mentioned in the article, and the relevant migration value still needs further verification.

Information source:Synergistic Optimization of Hot Molding Process and Lay‐Up Design of CFRP‐Steel Composite Load Wheel， Organized by Herun Chemical.