advanced gmt applications in the automotive industry richard broo quadrant plastic composites, inc....

Advanced GMT Applications in the Automotive Industry

Richard BrooQuadrant Plastic Composites, Inc.

Harri Dittmar

Quadrant Plastic Composites AG

SPE Automotive Composites Conference

Content: Cost Saving in the Automotive Industry Benefits of Advanced GMT Applications (GMT and

GMTex) Definition and Material Basics of GMTex Product and Process Information Impact Performance Current Applications Future Developments Summary

Advanced GMT ApplicationsAdvanced GMT Applications


Cost Saving - which costs are we talking about? Material costs: not useful, since the amount of material

needed for a certain part is different between metals and composites

Part costs: misleading, since plastic and composite parts usually have a higher degree of functionality compared to metal parts (even reduced number of parts)

Costs for defined functions: also not a good measure, since assembly costs are not taken into account

Proposal: to compare different materials for a certain application, costs for the final assembled part having the same number of functions like the metal part or group of parts are the best measure (examples: frontend and roof module)

Cost Savings for OEM`s with Advanced GMT Applications: Weight saving (improved fuel economy) High degree of function integration (less parts, reduced

logistics) Reduced assemly effort (belt length) and costs High productivity of part production (cycle times: 20s @

2 mm wall thickness) Low tooling costs compared to steel stamping tools

(better efficiency for cars with low production numbers: < 100 000 cars per year)



Benefits of Advanced GMT Applications: Cost and weight savings like for plastics in general but

use of parts out of advanced GMT possible:

• at elevated temperatures

• under creep loads

• under fatigue loads

• impact conditions (energy management)


Material Basics: Definition of GMTex GMTex is a combination of classical mat-based GMT with

one or more layers of endless fibers as woven fabrics or non-crimped stitched products out of various fibers

Twintex

Glass fabricGlass-Aramide non-crimped

PET special weave


Material Basics: Single Ply Design of GMTex The number and orientation of endless reinforcing fibers in

a single textile layer of GMTex can be tailored according to the requirements of the specific application:

0

15000

0°

45°

90°

135°

180°

225°

270°

315°

E-Modulus of PP-GM40

0

15000

0°

45°

90°

135°

180°

225°

270°

315°

E-Modulus of GMTex

Advanced GMT ApplicationsAdvanced GMT Applications Material Basics: Laminate Design of GMTex

Tailoring of properties by variation of type and number of reinforcing textile layers:

0

10000

20000

30000

40000

50000

GMT 40% GF

UD-GMT 40% GF

UD-GMTex 60% GF

UD-GMCTex 30% GF-20%

CF

Ten

sile

stif

fnes

s (M

Pa)


Production of GMTex:

Extruded PP-films

Double Belt Press

Glass mats

Textile reinforcements

Advanced GMTGMTex

Surface-layer

Middle-layer


Molding of GMTex:

Hot air oven Preheated blanks in the mold

GMTex blanks

Position of fabrics in the molded part

Molded part

Preheated blank

Impact Performance - Lancia Y Door Module


Excellent crash resistance and stiffness Integrated hip protection Multiple fixation devices, snap fits for wiring Door and window opening system guidance High productivity ( > 1000 parts/day) Recyclability

Tier 1: Lames Molder: Rangerplast Italy

Part weight: 1,5 kg



PP-GM40 (serial material), PP-GM30 DLFT 40% glass content LFT pellets (Stamax) 40% glass content GMTex and PP-GM30

Tested materials:

GMTex Toplayer 1/1, +/-45° (only for hip protection tests)

GMTex stripes Middle-Layer

GMT 30%

Blank layout for GMTex:



Crashtests carried out in cooperation with Rangerplast Italy to evaluate capabilities of GMT and GMTex in comparison to other materials

Side impact test (pole test) with clamped parts, fixations can rotate

Hip protection pad impact, flat impactor on barrier behind


GMT 40% @ 400J - Max. Absorption 800 J GMTex ML @1000J - Absorption 1000 J

D-LFT 40% @400J - Absorption 250 JSTAMAX 40% @400J - Absorption 120 J

Comparison of energy absorption and failure behavior at side impact test

Crash-Video Crash-Video



GMT 40% @ 400J - Max. Absorption 800 J GMTex ML @1000J - Absorption 1000 J

D-LFT 40% @400J - Absorption 250 JSTAMAX 40% @400J - Absorption 120 J

Comparison of energy absorption and failure behavior at side impact test


Side impact energy absorption

0

200

400

600

800

1000

1200

Stamax 40% D-LFT 40% GMT 30% GMT 40% GMTex ML

J Side impact

GMTex performance is limited by weak fixation points !

Results of side impact tests:


GMT 40% @ 1200 J - max. absorption 900 J

Comparison of energy absorption and failure behavior at hip pad impact test

GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

STAMAX 40% @ 900 J - max. absorption 450 J D-LFT 40% @ 900 J - max. absorption 500 J




Results of hip pad impact tests:

Hip pad impact energy absorption

0

200

400

600

800

1000

1200

1400

Stamax40%

D-LFT 40% GMT 30% GMT 40% GMTex ML

J

Hip pad impact

Brittle failure !

Current Advanced GMT Applications Structural Instrument Panels Seat Structures Battery Boxes Bad Road Engine Noise Shields Spare Wheel Wells Hatchback Doors Bumper Beams Rear Axle Supports


Excellent crash resistance and stiffness

In-molded cross-car beam Integration of functions +

fixations : air ducting, airbag and glovebox support, knee bolster, air conditioning

LL / RL utilisation same part Weight reduction (2 to 3 kg per

component) High productivity ( > 1000

parts/day) and low cost tooling Recyclability

Tier 1: Faurecia Molders:

Nishikawa (Mazda)Faurecia (Ford)FPK (Volvo)

Part weight: 3,2 - 3,5 kg


Current Applications: Structural Instrument Panel - Ford C1 Platform (Mazda 3, Ford C-Max, Volvo S40/V50)


Current Applications: Front Seat Base and Seat Back (Bentley Continental GT)

Excellent crash resistance and stiffness

Cost savings compared to steel and aluminum tooling due to low car production numbers

Weight reduction compared to steel High productivity ( > 1000 parts/day) Recyclability

Molder: Polynorm UK

Part weights: 1,1 / 1,3 kg


Current Applications: Battery Box (Porsche Cayenne and VW Touareg)

Molder: Rangerplast Italy

Part weight: 2,1 kg Excellent crash resistance: battery with

a weight of 30 kg is dropped from 300 mm into the box - no damage

Weight reduction High productivity ( > 1000 parts/day)

and low cost tooling Recyclability

Advanced GMT ApplicationsAdvanced GMT Applications Current Applications: Bad Road ENS: Audi, BMW, DC, Rover

Engine Protection Shield Audi C5

GMTex with polyester weavegives extreme wear and

impact resistance


Current Applications: Spare Wheel Wells (DaimlerChrysler C-/E-/S-Class, VW, Audi)

Excellent crash resistance, stiffness and fatigue strength

Bonded into BIW with PUR adhesive used for glazing

Weight reduction Better acoustics compared to

steel No additional corrosion

protection High productivity ( > 1000

parts/day) and low cost tooling Recyclability

Molder: Aksys Part weight (C-Class): 4,2 kg


Current Applications: Hatchback Doors (Nissan Stagea)

- Weight saving vs steel- Improved crash behavior due to GMTex- Hinges attached to steel profile- Narrow profile gives better rear visibility- Thin ribs due to improved GMT flow


Current Applications: Hatchback Doors (Nissan Murano)


Current Applications: Hatchback Doors (Nissan Infinity FX45)

Designs of Murano and Infinity hatchback doors in steel not feasible


Current Applications: Bumper Beams (Peugeot 407)

History 1: 805 with additional metal brackets

History 2: 806 with integrated brackets

407 with integrated brackets and crash absorbers for Allianz / Daner ranking


Current Applications: Rear Axle Support (All Volvo AWD Models)

- Weight reduction: 2 kg GMTex vs. 3 kg aluminum- Improved fatigue: 3 x the lifetime of aluminum

Top

Bottom

Side


Future Developments of Advanced GMT Applications (Informations can be disclosed):

Motor Supports Lower Leg Beams for Pedestrian Protection Rear Seat Backs with integrated seating belt


Future Developments: Motor Supports (Volvo Test Fleet, 20 Taxis at Göteborg)

Weight reduction: 31% (14 vs. 20,5 kg) withfirst prototypes using only random GMT -the use of GMTex will reduce the weight further

Longterm creep and fatigue tests performed before driving tests


Future Developments: Pedestrian Protection Beam (VW: various models)

- Cost & weight savings vs. steel and foam - Superior impact properties vs. LFT / IM / ICM


Future Developments of Advanced GMT Applications (Informations cannot be disclosed):

Structural Front Ends Rear (Wall) Modules Parts for a „3rd Crash Level“ Airbag Containers Airbag Covers Fire Walls Floor Modules


Summary: Advanced GMT-applications using GMT and GMTex show

already their performance in existing cars Cost and weight savings are the key benefits for the

automotive industry using these materials Compared to materials like (D)LFT, IM and ICM these

materials show superior properties like stiffness, impact, creep and fatigue

High flexibility of reinforcement fibers, type and number of textile reinforcements gives efficient tailoring of properties

New and challenging applications are under development and will be in the market in the coming years

advanced gmt applications in the automotive industry richard broo quadrant plastic composites, inc....

Documents

j absorption

gmtex slide

year advanced gmt applications

advanced gmt possible

capabilities of gmt

definition of gmtex

j stamax

impact test slide