new developments for mass production of epoxy automotive ... - … · 2016. 1. 12. · …at a...
TRANSCRIPT
New developments for
mass production of epoxy
automotive composites Alex Schmidt
Senior Development Engineer
Composites Europe 1
Composites Europe Forum 2016
1 DECEMBER 2016
…at a glance
$3.6 billion
4300 people
60 production sites
Hexion is a Specialty Chemicals Company with a
leading position in the development and production of
systems, products and services for
Weight reduction and Protection in the
Energy, Transportation and Construction markets
Technology Platforms
Epoxy
Phenolics
Versatics
Formaldehyde
Automotive
Lightweight Composites
Under The Hood parts
Suspension
Braking
Rubber goods
Coatings E-Coat to Clear Coat
Composites Europe 2 1 December 2016
Global Leadership Positions Across a Broad Range of
Technologies and Industries with Blue-Chip Customers
Oilfield Proppant Resins Global
Phenolic Specialty Resins Global
Versatic™ Acids & Derivatives
Global
Forest Product Resins Global
Epoxy Resins Global
Specialty Epoxy
Base Epoxy
Leading Market Positions Customer Base
LEADING MARKET POSITIONS IN MORE THAN 80% OF ITS REVENUE BASE
Interior Parts
Composites Europe 3 1 December 2016
The car industry implements light weight
solutions to comply with CO2 emission and
fuel consumption reduction legislation
Composites Europe 4 1 December 2016
Composite technology developments
enable mass production of automotive parts
Composites Europe 5 1 December 2016
Composite technology innovations
offer you cost-efficient light-weighting
Composites Europe 6
Composites:
Offer highest weight reduction opportunities in automotive applications
Innovative processing technologies:
Enable mass production of automotive parts
1 December 2016
Carbon Fibre Reinforced Plastics (CFRP)
has the highest weight reduction potential
Composites Europe 7
Sources: McKinsey Lightweight, heavy impact 2012;
Roland-Berger, 2012
100
80
80
60
50
0 20 40 60 80 100
Steel
HSS
Plastics
Aluminum
Carbon fiber
Part weight | % of steel
Typical cost build-up
50% material • 40 - 45% carbon fiber
• 5 - 10% resin
50% processing • Quicker curing matrix
• Process optimization
• Near-end-contoured preforms
• Automation
1 December 2016
The BMW 7-Series Carbon Core illustrates
body-in-white mixed material use
8
BMW 7-Series Various CFRP parts e.g. roof arc and tunnel reinforcement BMW SOP: 2015
Composites Europe
Source: BMW Group
Benefits • 40 kg weight reduction vs. steel in the Carbon Core body structure
• Fast curing cycle enabled by Hexion’s latest resin technology
• Multi material mix – engineered to performance
1 December 2016
Composite technology innovations offer
you cost-efficient light-weighting
Composites Europe 9
Composites:
Offer highest weight reduction opportunities in automotive applications
Innovative processing technologies:
Enable mass production of automotive parts
1 December 2016
Optimum CFRP performance and cost
is complemented with good design
Composites Europe 10
Process Capability
For OEM Industrialization
Materials Partnerships
Through Value Chain
Optimum
Performance
and Cost
Liquid resins
Epoxy Resins:
Hot melts
Perform Binders
Mould Release Agents
Prototyping systems
Phenolic Engineering Thermosets
Injection Moulding LCM Compression Moulding Prepreg HP-RTM
Performing SMC FiWi Towpreg
Equipment suppliers
Part Design and Modeling
Process Design and Modeling
Tool Building
Reinforcements
1 December 2016
Epoxy CFRP with Resin Transfer Moulding
(RTM) technology for structural applications
11 Composites Europe
Audi R8 Coupe and Lamborghini Huracan (MSS Platform)
CFRP Transmission Tunnel
ACE
EPIKOTE™ Resin TRAC 06150/
EPIKURE™ Curing Agent TRAC 06150
Benefits • 30% lighter than aluminium
• Short cycle time
1 December 2016
RTM technology enables fast production
of highly complex structural parts
Composites Europe 12
Mould closing and resin injection • Thermal latency
• Low viscosity
• Rapid fibre wetting
Curing • Fast conversion
• Isothermal
• Low exotherm
Opening and de-moulding • Easy de-moulding
• Part quality
• Reproducibility
Lay-up binder stabilized fabric
Heating and some pressure • Fast handling
• Textile stability
• Controlled permeability
1 December 2016
Epoxy binders address preforming
challenges in fast RTM
Composites Europe 13
Benefits
• Faster handling/positioning
• Controlled permeability and lay-up definition
• Textile stability at mould temperature
1 December 2016
The part size and equipment determine
the material processing window
Composites Europe 14
Part
0
1000
2000
3000
4000
5000
6000
7000
0 20 40 60 80 100 120
Resin Injection rate (g / sec)
60 g/s
Injection time (sec)
Resin Shot weight (g)
EP TRAC 06170
EK TRAC 06170
33 sec
EP TRAC 06150
EK TRAC 06165
45 sec
EP TRAC 06150
EK TRAC 06150
95 sec
80 g/s 100 g/s
80% of
Moulded parts
Equipment
Material
1 December 2016
Epoxy CFRP with RTM & LCM technology
for structural applications
15 Composites Europe
BMW 7-Series
CFRP roof arc
EP TRAC 06000/
EK TRAC 06130
Benefits
• Local reinforcement enhances
torsional stiffness
• Fast curing cycle with LCM
BMW 7-Series
CFRP tunnel reinforcement
EP TRAC 06000/
EK TRAC 06130
Benefits
• Designed to the shape of the car body
• Fast curing cycle with HP-RTM
• Outstanding weight / performance ratio
1 December 2016
LCM: Preforming is simplified and direct
liquid resin application shortens the cycle time
Composites Europe 16
Transfer wet lay-up into mould
Curing
• Controlled viscosity built
• Fast conversion
• Low exotherm
Opening and de-moulding • Easy de-moulding
Lay-up dry fabrics
Liquid resin application
• Tailorable latency
1 December 2016
Liquid Compression Molding (LCM) is cost
attractive with increasing complexity of parts
Composites Europe 17
Low Part complexity
Cost
Pre
form
requirem
ents
Pro
cess c
om
ple
xity
High
High
RTM
LCM
1 December 2016
Part to part cycle times of 50 seconds have
been demonstrated with LCM
ACCE
7 Sept. 2016 18
Press closing
Impregnation
Curing
Press opening
Part to part cycle times of 50 seconds have
been demonstrated with LCM
Composites Europe 19 1 December 2016
Epoxy CFRP with RTM & SMC technology
for semi-structural applications
Composites Europe 20
JEC Award Winning CFRP Decklid Demonstrator
Continental Structural Plastics (CSP)
EP TRAC 06170/EK TRAC 06170
Benefits • Weight reduction of 13% compared to aluminum
• Short cycle time
• Combined material technologies: CF RTM inner and SMC outer
1 December 2016
Improved cost efficiency of SMC technology
net shape moulding without preforming
Composites Europe 21
SMC Cutting & moulding • Lower scrap rate than RTM
• Hybrid reinforcement
• Functionalization
Pressing • Short in mould cycle times
• Controlled flow
• Netshape
Part de-moulding • Low shrinkage
• High strength/modulus
• Reproducibility
Component mixing
SMC compounding • Good fibre wetting
• Potential use recycled fibre
• Fast maturation
• Low Viscosity
• No VOC (styrene free)
1 December 2016
EPIKOTE™ Resin Systems have
benefits in SMC
Composites Europe 22
Epoxy benefits versus
vinylesters and unsatured
polyesters
• No VOC and styrene free
• Inherently low shrinkage
• Better mechanical strength properties
• Good adhesion to glass and carbon fibre
• Compatible with other material Epoxy
technologies
• Higher Tg
• Higher fatigue/durability performance
1 December 2016
Epoxy CFRP with prepreg technology
for semi-structural applications
23 Composites Europe
Forward Light Holders
CMP GmbH - UBC GmbH
EP TRAC 06425/
EK TRAC 06465
Mini Front Wings
CMP GmbH - UBC GmbH
EP TRAC 06425/
EK TRAC 06465
Performance Benefits • Lightweight versus steel
• Short cycle time (90 sec or 3–5 min)
• High performance
• High Tg
Processing Benefits
• Long shelf life at room temperature
• Easy and versatile moulding
• In house prepreg as viable approach
to further reduce cost
1 December 2016
High mechanical performance is
achieved with prepreg technology
Composites Europe 24
Cutting & moulding • Low scrap rate
• Hybrid reinforcement
• Functionalization
Pressing • Short in mould cycle times
• Controlled flow
• Netshape
Part de-moulding • Low shrinkage
• Mechanical performance
• Reproducibility
Impregnation
Fibre or prepreg placement • Easy fiber positioning
• Stable band width
• Good fiber wetting
• Low Viscosity
• No VOC
• No preforming
1 December 2016
25
Complex structural components can be
manufactured with prepreg technology
Epoxy CFRP
for exterior applications
JEC World 2016 26
Porsche 911 GT3
Door
Benteler SGL
SOP: 2013
Benefits
• Lightweight
• Lower center of gravity
• Class A appearance
• Hot wet resistance
• Carbon fiber aesthetic / styling option
BMW
Roof Panel
M3, M6
SOP: 2004
Lamborghini Aventador
Bonnet
ACE
SOP: 2011
8 March 2016
Epoxy CFRP
for suspension applications
JEC World 2016 27
Mercedes Sprinter
Leaf Spring
IFC Composites
SOP: 2006 & 2013
Benefits
• Weight reduction 4.4 kg
• Smoother riding with improved precision
• Failsafe design
• Inherently corrosion-free
• Low carbon footprint
Audi A6 Avant 2.0 TDI Ultra
Coil Spring
S.ara Composites – SOGEFI
SOP: 2014
Benefits
• Weight reduction of 14 kg
• High volume capable
• Improved vehicle NVH
• Corrosion resistance
• Hot-wet resistance
8 March 2016
Key takeaways
Composites Europe 28
Epoxy Fibre Reinforced Composites:
Highest weight saving potentials
New generation resin systems:
Faster cure cycles, easier demoulding and more process versatility
Design and consolidation of component:
Will continue to decrease cost per kg weight saving
1 December 2016
DISCLAIMER
The information provided herein was believed by Hexion Inc. and its affiliated companies ("Hexion") to be accurate at the time of preparation or prepared from sources believed to be
reliable, but it is the responsibility of the user to investigate and understand other pertinent sources of information, to comply with all laws and procedures applicable to the safe
handling and use of the product and to determine the suitability of the product for its intended use. All products supplied by Hexion are subject to Hexion's terms and conditions of
sale. HEXION MAKES NO WARRANTY, EXPRESS OR IMPLIED, CONCERNING THE PRODUCT OR THE MERCHANTABILITY OR FITNESS THEREOF FOR ANY PURPOSE
OR CONCERNING THE ACCURACY OF ANY INFORMATION PROVIDED BY HEXION, except that the product shall conform to Hexion's specifications. Nothing contained herein
constitutes an offer for the sale of any product.
© 2015 Hexion Inc. All rights reserved.
® and ™ denote trademarks owned or licensed by Hexion Inc.
Thank you!
Composites Europe 29
Innovation Built on Collaboration
Your Partner in Composite Resin solutions
Alex Schmidt
Senior Development Engineer
1 December 2016