Sorry for the “greek” ... bad habit of mine ... Polysialate is a Geopolymer or Cementious compund that when cured binds the fibers together AND retains ~75% of it’s mechanical properties at 750c ..at ~20% of the cost of Epoxy ...
The bonus that I wanted to illustrate was ~ 60% mass/weght reduction of the OEM steel frame, with equivalent stiffness, increased strength (impact/crash), better NVH, and no corrosion or degradation (20-25y life ... before global stiffness begins to degrade NVH) the requirement to bond all but 5 pieces of the ASSY means that the delivered Frame must be dimensionally conforming at all HDPTs ...
The downside of this effort would be that a newly produced frame will have a premium new frame cost point. The ability to “standardize” the ~ 40 components in a typical frame would permit amortized Testing/ Engineering and Tooling/Mould costs to be distributed over a larger number of frames ... Jeep + other Ladder Frames ... I hve not completed this excercise but feel a small (~20%) MRSP premium over NOS OEM steel can be realized with about 5 Frame configurations at a rate of 50/y for each of the 5 Frame Models) The frame cost will lower with higher production rates, however rates >500/y require automation which will increase min quanties/y ...
There are a number of Stateside Bond Shops that I use for developmental manufacturing .. however realistic end user interest needs to be defined ... the Jeep Wranglers, Toyota Tacomas, and Nissan Frontiers/Navarra Frames are also being targeted...
I have a JK (2D) FEA Deformation Simulation (contour eye candy plots) that I will upload this coming week..
I really would like feedback regarding the end-use values for weight savings, corrosion elimination, nd NVH improvement, complete dimensional conformity of the requested Suspension Mounting HDPTs, and imprved NVH.
regards r/