gf automotive ag carbon fiber: a thread or opportunity for lightweight...

GF Automotive AG

Carbon Fiber:A thread or opportunity for Lightweight Castings

Klaus Decking

04/2015 | K. Decking

Georg Fischer

Corporation

� More than 210 years of history, founded in 1802

� Three core businesses, Piping Systems, Machining Solutions and Automotive

� 124 companies around the globe

� Sales of CHF 3.8 billion in 2013

� 14 000 employees

2


Our diversified profile

37%CHF 1 415 million

24%CHF 905 million

39%CHF 1 476 million

GF Piping Systems GF Automotive GF Machining Solution s

Three times premium expertise and service to match our customers’ needs:

Total sales in 2014: CHF 3 795 million

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� Production of lightweight castcomponents and systems

� Made out of ductile iron, aluminumand magnesium in sand casting andhigh pressure die casting

� For the global automotive industryand other industrial applications

4 898 employees

10companies worldwide

1 415 million (CHF) sales

GF Automotive


Figures for 2014

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GF Automotive

Casting or Carbon Composites?

Repair

Herstellung

Recycling Material Cycle

Lower Energy Consumption

Resistance

Costs

Production

Lighter

Corrosion Resistance

Repair

Recycling

CarbonIron

Aluminum

Magnesium

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GF Automotive

Material Comparison

GJS 400-15GJS 450-10

SiboDur700-10

Aluminum Magnesium Carbon Fiber

Tensile Strength Rm (N/mm2)

Min. 400-450 Min. 700 277-338 217.5-230 3530-4560

0.2%-Yield Stress Rp 0,2(N/mm2)

Min. 250-310 Min. 440 142-196 112.5-155 -

Elongation (%)

Min. 10-15 8-12 3.5-12.5 3.5-10 1.1-1.5

Young’s –Modulus (kN/mm2)

175 175 72-77 43-45 230-395

Density(g/cm3)

7.1 7.1 2.6-2.7 1.8 1.8

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GF Automotive

Lightweighting Potential

Source University of Cambridge

Weight Reduction

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GF Automotive

Production Chain of Carbon Fiber and Magnesium

Carbon Fiber

Magnesium

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GF Automotive

Manufacturing Climate Balance Sheet

CO2 Emissions


Due to pidgeonprocess

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GF Automotive

Manufacturing Energy Consumption

Energy Consumption


Energy Consumption

Due to pidgeonprocess

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GF Automotive

Emission over Life-Cycle


Change of Perspective: Break-Even

Source: VW, University of Cambridge

Break Even:

0 km High Strength Steel

90.000 km Aluminum

120.000 km Magnesium

170.000 km Carbon Fibre

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GF Automotive

Availability

Carbon fiber : Uses polyacrylonitrile

Magnesium : 8th abundant element in earth’s crust

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Carbon Fiber Metals

GF Automotive

Recycling

Fully recyclableUsed in new alloysUsed as a mixture in new alloys

Recyclable?At least downcycling or scrap

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GF Automotive

Repair Job

Metal Repair

Carbon Fiber Repair

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GF Automotive

Cost Comparison

Costs per Part (in % of Steel)

Steel

Aluminum

Magnesium

Carbon

100

130

155

570

Source: McKinsey&Company, Magnesium own ResearchUniversity of Cambridge

Up to 3 times higher costs for carbon fibre

With new precursors and technological progress improving production processes, a decrease of almost 30% in the global cost of composites is expected between now and 2020

Today

Tomorrow

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GF Automotive

Carbon Fiber vs. Aluminum

Source: BMW AG

100% Carbon?

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GF Automotive

Substitution of Sheet Metal Constructions

Weight ReductionCasted aluminum compared to steel sheet assembly out of 10 parts up to 45% less weight


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GF Automotive

Carbon Fiber vs. Magnesium

- 30% Weight Reduction compared to conventional Steel-based Designs

Carbon Fiber Magnesium

- 30% Weight Reduction compared to conventional Steel-based Designs

Source BASF

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GF Automotive


Weight ReductionSeat frame in casted Magnesium up to 30% less weight than metal sheet assembly


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GF Automotive

High Design Freedom for Castings

Front Steering Knuckle

Carbon- 40%

Iron- 35%

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GF Automotive

Bionic Design

Weight reductionIron steering knuckle up to 35% less weight through bionic design


++

++

+

-

++

++

Iron / Steel

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GF Automotive

Material Strengths and Weaknesses

Costs

Recycling

Energy Consumption

Weight Reduction

Repair

Strength +

+

o

+

+

+

o

o

-

++

+

o

++

--

-

++

--

--

Aluminum Magnesium Carbon

GF Automotive

Design

04/2015 | K. Decking23

(Quelle: Prof. Dr. Claus Mattheck)

Principle

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Start

Topological Optimization

CAD

Bionic Design

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Bionic Design

-12,5 %

Before

GJS 7007,2 kg

After

SiboDur® 7006,3 kg

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GF Automotive

Substitution of Aluminum throughMagnesium in Powertrain Applications

Weight reductionFront cover in castedMagnesium up to 45% lessweight than aluminum


04/2015 | K. Decking27

GF Automotive

Process

Know how to cast

Material

Des

ign

Prozess

Val

idie

rung

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Substitution of System Parts

Weight ReductionCrossmember, completely casted in iron has 17% less weight than combined assembly out of steel sheet and iron


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Weight ReductionInno Door Frame in casted Aluminum up to 40% less weight than metal sheet assembly


WeightReductionPotential

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Casting Advantages

Design Freedom +

Variation of Wall Thicknesses

100% Recyclable

Cost Efficiency –Mass Production for

complex Parts

FunctionalIntegration

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Joining of Parts in the Body Structure

• Screwing• Compound casting• Electro magnetic forming• Clinching• Adhesives• Delta-spot welding

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Lightweight Design by Multi-Material Mix: Metal / Plastics

CastingPlastic

Housing

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GF Automotive

… for your

Lighter Future

Passion …

ContactKlaus DeckingHead of Marketing, Communication & ServicesBusiness Development New MarketsPhone +41 52 631 21 17Mobile +41 79 633 11 37Fax +41 52 631 28 [email protected]

GF AutomotiveGeorg Fischer Automotive AGAmsler-Laffon-Strasse 98201 SchaffhausenSwitzerlandwww.gfau.com

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GF Automotive

Disclaimer

This document is for presentation purposes only and should not be construed as an offer, invitation or solicitation to subscribe for, purchase or sell any investment. Neither it noranything it contains shall form the basis of any contract whatsoever.

Opinions expressed herein reflect the current judgement of the management of Georg Fischer. The presentation contains forward-looking statements that involve risks and uncertainties. Theactual results of Georg Fischer may differ materially from those anticipated in these forward-looking statements and forecasts as a result of a number of factors.

The management of Georg Fischerdoes not accept any liability whatsoever with respect to the use of this presentation.

gf automotive ag carbon fiber: a thread or opportunity for lightweight...

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