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VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013

Use of Continuous Fiber Reinforced Engineering

Plastics: The Seat Pan of the Opel Astra OPC

Jörg Schnorr, BASF SE, Dr. Ralf Langendorf, Adam Opel AG, Rüsselsheim, Jordan Kurikov, BASF SE, Ludwigshafen

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New Applications in Automotive with

Fiber Reinforced Engineering Plastics

Ultramid ®

Short fibers

Ultramid ® Structure

Long fibers

Semi-structural parts Structural parts

Developments supported by simulation tool ULTRASIM ®

Polyamide with continuous fibers

(Tape/Laminate + Overmolding)

VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 2

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Continuous Fiber Reinforcement

of Injection Molded PartsTypes of Semi Finished Products

UDTape

Thermo-

plastic

laminate

Laying of tapes

(picture AFPT)

Organosheet

(picture IVW)

Reinforced plastic

molding

Reinforced

plastic molding

ReinforcerPultruded Tape

fully impregnated

Heating One Shot Draping

and Overmolding


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4

0

20

40

60

80

100

120

140

0 200 400 600 800 1000 1200 1400 1600 1800

S t i f f n e s s [ G P a ]

Strength [MPa]

Al

Mg

PA-GF50

PA-GF30

Laminates 0/90 GF

Laminates 0/90 CF

All materials 50 Vol.-% fiber content

Strength [MPa]

S t i f f n e s s [ G P a ]

Source: Fiberforge

Potential of continuous fiber reinforced plastics Carbon vs. glass fibers --- Stiffness vs. Strength


UD-Tapes CF

UD-Tapes GF

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Joint development and production ofthermoplastic composites:

UD-tapes and laminates

BASF: Know-how in research, productionand formulation of thermoplastic resins

TenCate Advanced Composites:

Expertise in composite manufacturing

Advanced tapes and laminates…

For structural automotive parts

(car body, chassis)

Focus on mass production

BASF and TenCate: Strategic Alliance for

Thermoplastic Automotive Composites


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Measurement Process

Draping / Molding

Material

Part

Integrative Simulation ULTRASIM®for Continous Fiber Reinforced Plastics

BASF approach: full ULTRASIM®

prediction and design level for

continuous fiber reinforcement


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Material Characterization for ULTRASIM®Laminates and Tapes

Tensile Test

Orientation

Testing Speed

(Wallthickness)

Humidity

3 Point Bending

Puncture Test

Compression Test

Sheartest

Adhesion of Ribs

Draping


Drapiereigenschaften

IVW, Kaiserslautern

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Ultrasim ® Helps to Optimize the Design of

Plastic Parts

Anisotropic

Nonlinear

Strain-rate sensitive

Tension-compression asymmetric

Failure modeling

Process simulation

Mechanical simulation

Mathematical optimization

(parameter, shape, topology)

ULTRASIM ®

Calculate the part right Calculate the right part

Material modelling -

Integrative Simulation CAE Methods +

Mathematical Optimization


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0

6

12

18

24

30

36

0 10 20 30 40 50 60 70 80

Force

Way

Simulation

Experiment

VDI International Congress Plastics in Automotive Engineering Mannheim, 13.-14. März 2013 9Ultramid ® Structure

Ultrasim ® Predicts Energy AbsorptionPost Failure Behaviour

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Which Type of Semi Finished Material?

Tapes

Parts with areas of highest local

anisotropic load distribution

e.g. front seat backrests

Laminates

predominantly closed areas, mechanicalload rather evenly distributed

e.g. seat pans, rear seat backrests,

vehicle floors


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Example: Prototype-Seat Backrest with

overmolded Tape Reinforcement

UD- Fiber reinforcement in high loaded zones

Injection molding material in zones of medium load and functional integration

Injection

molded PA6

UD-Fiber

reinforcement

Overmolded in

injection molding

process


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Automated TapelayingAvailable Processes

Moving Headwith laser welding fixation

Moving Tablewith ultrasonic fixation


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Consolidation of TapesMicroscopy und Micro-CT

glass fibers matrix: PA6 Ultramid ®

6-layers: 0°/90°/0°/0°/90°/0°

thickness 0,25mm each

60 weight-% glass fibers

before Consolidation


after Consolidation

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Component Test and ValidationDynamic Test, 5.0 m/s Impactor Speed

After Test

Break between bolts in bothCAE and Test

CAE


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Drop Tower TestInfluence of Fiber Length

0

100

200

300

400

500

600

700

0 10 20 30 40 50 60 70

Time [ms]

E n e r g y

[ J ]

PA6 GF50 23°C

PA6 LGF40 23°C

PA6 CFRT 23°C

Test Temperature 23°C

Ultramid®

Ultramid® Structure

Ultramid® + Reinforcer


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Drop Tower Test Influence of Overmolding Material

„Ultramid® 1“

„Ultramid® 2“

„Ultramid® 1“

specific developed

impact modified grade

„Ultramid® 2“


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Further Potential in Vehicles

Structures for doors

and hatches,

even onlinepaintable


Crash

Extensions

StructuralFloor

Structural

Inserts (A-, B-,

C-Pillar, Roof

Frame…) Cross Car

Beam

Roof Cross

Member

Fire Wall

FrontendBattery

Integration

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Example:

Serial Front Seat Pan Opel Astra OPC


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Adam Opel AG

SeaTcon AG/

SedisTec UG

Reinert

Kunststofftechnik

Maier Formenbau

…

Example:



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Overmolding material Ultramid® PA6 short glass fiber material

Thermoplastic laminate based on

Ultramid® PA6 and glass fibers


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Ultrasim ® for CompositesIntegration of Relevant Process Steps


In-Mold Forming Injection Molding Mechanics

Integrative Simulation with ULTRASIM ®

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Optimization of Heating Parameters

Influence parameters:

Material properties (absorption,

reflection, thermoconductivity etc.)

Type of emitter

Emitter control (power profile)

Distance, time…

Trials at Krelus Infrared


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In-Mold-Forming and Overmolding

mold closing side mold injection sidelaminate in open moldIR heater


Cycle time 70 sec

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Micro CT Testing


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Component Testing

m = 25 kg

v = 5 - 9 m/s


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Seat Testing


Quelle: SedisTec

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Wall thickness 1 mm

in laminate

45% weight saving

Function integration

Cost balance

Serial Application in Opel Astra OPC


http://localhost/var/www/apps/conversion/tmp/scratch_4//upload.wikimedia.org/wikipedia/de/2/25/Opel-logo_mit_schriftzug_im_ring_2009.png

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Conclusion

Thermoplastic laminates can be used in serial production

processes for the automotive industry.

Properties of both semi finished material and overmolding

material determine part performance.

ULTRASIM® enables fast development of overmolded

continuous fiber parts even in crash relevant applications.

Hereby strengths of these materials can be used by far betterthan with standard methods.

Interesting weight and cost results can be reached in

automotive seats.


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„…die nahezu

perfekten,

18-fach

einstellbaren

Schalensitze“

http://www.auto-

motor-und-

sport.de/fahrberichte/

opel-astra-opc-

flitzlicht-gewitter-auf-

der-nordschleife-

5035812.html

download am

21.11.2012

Feedback


http://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.htmlhttp://www.auto-motor-und-sport.de/fahrberichte/opel-astra-opc-flitzlicht-gewitter-auf-der-nordschleife-5035812.html

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Future Outlook

Design Freedom with New Materials


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The information and data given here are based on our current knowledge and experience. This does not relieve the

purchaser of our products from incoming inspection. The information and data do not describe the suitability of the

product for a specific application. Composition - and durability statements - as well as any other statements are not to

be considered as a warranty.

The values contained herein are based on analysis/testing of laboratory test specimens and represent data that fallwithin the normal range of properties for natural materials, unless stated otherwise. Colorants and additives may alterproperties.

This information is provided as a service for comparative purposes only and in no way constitutes any productspecification or the like. For component design the data contained herein are applicable as guideline only.

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