17-8.09.2010

ACRC

CARBON FIBRE INNOVATION FOR HIGH VOLUMES:

THE FORGED COMPOSITE

CARBON FIBER IN AUTOMOTIVE MARKET

Automotive applications of carbon fibre reinforced plastics (CFRP) are increasing.

Lucintel, the premier global management consulting firm, revised upward its forecastof growth in the carbon fibre market from 9.8% per year over the next five years to13% per year.

BMW, Mercedes-Benz, Lamborghini and other high-end automakers havecommitted to the increased use of CFRP components in their vehicles to reduceweight.

Daimler has set a body in white weight reduction target of up to 10% for all of its

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Daimler has set a body in white weight reduction target of up to 10% for all of itsmodels and is looking to carbon fibre materials for some of that weight saving.

The SGL Group reported that sales in its Carbon Fibres & Composites businessincreased by 6% in the first nine months of 2010.The SGL Automotive Carbon Fibers GmbH joint venture with BMW is dedicated toproducing carbon fibre for BMW’s Megacity vehicle, the company’s first productionelectric car.The car is being called the world’s first large-scale production vehicle designed with aCFRP passenger cell.

CARBON FIBER IN AUTOMOTIVE MARKET

Mercedes-Benz has been using carbon fibre composites since 2004, when the seriesproduction of the SLR McLaren high-performance sports car was launched. Today, thelatest model, the McLaren MP4-12C supercar, features a CFRP MonoCell tub, mouldedas a single-piece that is designed to protect the occupants.

Chevrolet has introduced the 2011 Z06 Carbon Limited Edition Corvette, whichfeatures a carbon fibre hood, roof panel with a full-width body spoiler, rocker panelsand air splitters. But the 2011 Corvette ZR1 carries even more carbon content – eightcomponents with a total weight of 34 lbs (15.4 kg) or one half the weight of

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components with a total weight of 34 lbs (15.4 kg) or one half the weight ofequivalent glass fibre SMC [sheet moulding compound] parts.

Lamborghini has also stated that it intends to add more CFRP components to itsvehicles. A high priority is the development of out-of-autoclave curing to increase theproduction rate and reduce costs for future vehicle systems.Lamborghini recently introduced its CFRP demonstrator concept, the Sesto Elemento,which weighs only 999 kg (2204 lbs).

FORGED COMPOSITE – TECHNOLOGY OVERVIEW

FORGED COMPOSITE is produced by SSSSheet MMMMoulding CCCCompound process with carbonfibres (opposited traditional glass fibre SMC) It uses pre-fabricated sheet material madeof vinylester resin and short length carbon fibres (chopped fibers).

FORGED COMPOSITE should not be confused with traditional GF-SMC. The primaryadvantages of carbon fibers in FORGED COMPOSITE are higher modulus and lowerspecific gravity relative to glass fibers. The modulus of commercial-grade carbon fibersis more than four times higher than E-glass fibers!

FORGEDFORGEDFORGEDFORGED COMPOSITECOMPOSITECOMPOSITECOMPOSITE GFGFGFGF –––– SMCSMCSMCSMC ((((25252525%%%% GF)GF)GF)GF)TensileTensileTensileTensile strengthstrengthstrengthstrength 230 MPa 80 MPaYoung’sYoung’sYoung’sYoung’s ModulusModulusModulusModulus 55,000 Mpa 12,500 MPa

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Young’sYoung’sYoung’sYoung’s ModulusModulusModulusModulus 55,000 Mpa 12,500 MPaDensityDensityDensityDensity 1,48 Kg/dm3 2 Kg/dm3

FORGED COMPOSITE raw material

P=60 barT = 127 C

Curing time 5min

+ stiff+ design flexibility+ integration options

Manufacturing process Example: Sesto Elemento A-arms

Material Performance

Preforming into 1 carrier

Automatic preforming is possible

Material squeezed in the tooling by applying pressure about 60 bars

FORGED COMPOSITE – TECHNOLOGY OVERVIEW

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FC process

1. Cuttingof preforms

2. Preformingontocarrier

3. Apply chargein mouldby carrier

4. removecarrier

5. Mould 6. Eject /Part finished

• Resin comparison in plate characterisation

MASS PRODUCTION – THE FORGED COMPOSITE

30

345

37

75

5,25

60

80

100

120

140

Te

mp

era

ture

in

°C

Curing and Post RTM vs FORGED COMPOSITE press moulding

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75

0

20

40

0 50 100 150 200 250 300 350 400

Te

mp

era

ture

in

Time in min

Curing RTM/Press Moulding Hexion Post Curing Oven Hexion Curing RTM/Press Moulding Huntsman

Post curing Oven Huntsman Curing FORGED COMPOSITE/Press moulding

RTM vs FORGED COMPOSITE

RTM*

163 min

Prep Moulding Post-processing

Forged composite has very short curing time

Process time is reduced by 44% plus advantage of reduced part count

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0 100 200 300 400 500 600

Process time [min]

Process time

Forged

Composite

26 m

in

*: Process of 1 part (largest) part

- 44%

FORGED COMPOSITE – SAMPLE COSTS OVERVIEW

RTM TUB

100%

FORGED COMPOSITE TUB

110%Weight

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100 %

100 %

100 %

80 %

50 %

71 %

Normalizedmaterial cost

NormalizedManufacturing time

NormalizedPart price

THE “SESTO ELEMENTO”

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Technology demonstrator: 20 cars planned to be sold in 2011

Almost entirely carbon fiber composite structure

Dramatic weight reduction 999Kg vs. 1560 lb baseline

Innovative content

Carbon fiber wheel/ hubs

Wrapping Carbon fiber driveshaft

Integral carbon bodyshell in Forged Composite

New high temp carbon exhausts Pyrosic

THE “SESTO ELEMENTO”

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New high temp carbon exhausts Pyrosic

Forged composite technology in suspension arms

One-piece carbon monocoque

Integrated seats

Carbon crash box

Titanium fasteners vs. aluminum inserts

THE “SESTO ELEMENTO”

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Redesigned CFRP lower front Original forged aluminum lower

8 parts total (4 different designs), 2 fronts and 2

rears, 2 uppers and 2 lowers

Result: -30%, rate improved (total cycle time 3

mins), cost reduced ($32 per part)

THE “SESTO ELEMENTO” SUSPENSION ARMS

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Redesigned CFRP lower front suspension arm assembled and

finished

Original forged aluminum lower front suspension arm assembled and finished

Forged composite mechanical properties are not yet comparable with Pre-preg and

RTM standards

Lamborghini has completed material characterization and validation o f Hybrid

structures as follows:

FC + Unidirectional

FC + Fabric

FORGED COMPOSITE – HYBRID STRUCTURES

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FC + Fabric

Lamborghini is developing hybrid Forged composite panels to fulfil A-class surface

requirements

Combination of Forged composite with Unidirectional fibers gives the opportunity to

obtain parts fulfilling the automotive A-class surface requirements

� Composite mass production is already the present

� High performance composites materials combined with high volumes

production rate are achievable

� A class surfaces body panels under development

� Sesto Elemento shows the potential of the Forged composite in terms of:

FORGED COMPOSITE – CONCLUSION

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� Sesto Elemento shows the potential of the Forged composite in terms of:

� Production rate

� Costs

� Feasibility

� Structural behaviour

� Joining technology (Hi-Lok)

� Co- Bonding

� Forged Composite is the future of structural and non structural composite

application