CARBON FIBRE INNOVATION FOR HIGH VOLUMES: THE FORGED COMPOSITE ACRC

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Gavin Summers
7 years ago
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1 CARBON FIBRE INNOVATION FOR HIGH VOLUMES: THE FORGED COMPOSITE

2 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 forecast of growth in the carbon fibre market from 9.8% per year over the next five years to 13% per year. BMW, Mercedes-Benz, Lamborghini and other high-end automakers have committed to the increased use of CFRP components in their vehicles to reduce weight. Daimler has set a body in white weight reduction target of up to 10% for all of its models and is looking to carbon fibre materials for some of that weight saving. The SGL Group reported that sales in its Carbon Fibres & Composites business increased by 6% in the first nine months of The SGL Automotive Carbon Fibers GmbH joint venture with BMW is dedicated to producing carbon fibre for BMW s Megacity vehicle, the company s first production electric car. The car is being called the world s first large-scale production vehicle designed with a CFRP passenger cell. 2

3 CARBON FIBER IN AUTOMOTIVE MARKET Mercedes-Benz has been using carbon fibre composites since 2004, when the series production of the SLR McLaren high-performance sports car was launched. Today, the latest model, the McLaren MP4-12C supercar, features a CFRP MonoCell tub, moulded as a single-piece that is designed to protect the occupants. Chevrolet has introduced the 2011 Z06 Carbon Limited Edition Corvette, which features a carbon fibre hood, roof panel with a full-width body spoiler, rocker panels and air splitters. But the 2011 Corvette ZR1 carries even more carbon content eight components with a total weight of 34 lbs (15.4 kg) or one half the weight of equivalent glass fibre SMC [sheet moulding compound] parts. Lamborghini has also stated that it intends to add more CFRP components to its vehicles. A high priority is the development of out-of-autoclave curing to increase the production 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). 3

4 FORGED COMPOSITE TECHNOLOGY OVERVIEW FORGED COMPOSITE is produced by Sheet Moulding Compound process with carbon fibres (opposited traditional glass fibre SMC) It uses pre-fabricated sheet material made of vinylester resin and short length carbon fibres (chopped fibers). FORGED COMPOSITE should not be confused with traditional GF-SMC. The primary advantages of carbon fibers in FORGED COMPOSITE are higher modulus and lower specific gravity relative to glass fibers. The modulus of commercial-grade carbon fibers is more than four times higher than E-glass fibers! FORGED COMPOSITE GF SMC (25 25% GF) Tensile strength 230 MPa 80 MPa Young s Modulus 55,000 Mpa 12,500 MPa Density 1,48 Kg/dm 3 2 Kg/dm 3 P=60 bar T = 127 C Curing time 5min + stiff + design flexibility + integration options FORGED COMPOSITE raw material Manufacturing process Example: Sesto Elemento A-arms Material Performance 4

5 FORGED COMPOSITE TECHNOLOGY OVERVIEW Preforming into 1 carrier Automatic preforming is possible Material squeezed in the tooling by applying pressure about 60 bars 1. Cutting of preforms 2. Preforming onto carrier 3. Apply charge in mould by carrier 4. remove carrier 5. Mould 6. Eject / Part finished FC process 5

6 MASS PRODUCTION THE FORGED COMPOSITE Resin comparison in plate characterisation 140 Curing and Post RTM vs FORGED COMPOSITE press moulding 120 5, Temperature in C 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 6

7 RTM vs FORGED COMPOSITE Forged composite has very short curing time Process time is reduced by 44% plus advantage of reduced part count Prep Moulding Post-processing RTM* 163 min Forged Composite 26 min - 44% Process time [min] *: Process of 1 part (largest) part Process time 7

8 FORGED COMPOSITE SAMPLE COSTS OVERVIEW RTM TUB FORGED COMPOSITE TUB Weight 100% 110% Normalized material cost 100 % 80 % Normalized Manufacturing time 100 % 50 % Normalized Part price 100 % 71 % 8

9 THE SESTO ELEMENTO 9

10 THE SESTO ELEMENTO Technology demonstrator: 20 cars planned to be sold in 2011 Almost entirely carbon fiber composite structure Dramatic weight reduction 999Kg vs lb baseline Innovative content Carbon fiber wheel/ hubs Wrapping Carbon fiber driveshaft Integral carbon bodyshell in Forged Composite 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 10

11 THE SESTO ELEMENTO 11

12 THE SESTO ELEMENTO SUSPENSION ARMS 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) Original forged aluminum lower front suspension arm assembled and finished Redesigned CFRP lower front suspension arm assembled and finished 12

13 FORGED COMPOSITE HYBRID STRUCTURES 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 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 13

14 FORGED COMPOSITE CONCLUSION 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: Production rate Costs Feasibility Structural behaviour Joining technology (Hi-Lok) Co- Bonding Forged Composite is the future of structural and non structural composite application 14

Carbon Fiber Composites Low Cost Materials & Manufacturing Options

Carbon Fiber Composites Low Cost Materials & Manufacturing Options George Husman Zoltek Companies, Inc. September 13, 2012 1 Carbon Fiber Markets All China Hexcel Formosa SGL Cytec AKSA Others 2011 Estimated