One Pathway to Lightweight Composite Cars. Dr. Martin Jung // Senior Vice President Structural Materials

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1 One Pathway to Lightweight Composite Cars Dr. Martin Jung // Senior Vice President Structural Materials

2 American Chemistry Council ACC is the leading trade association for the $770 billion chemical industry ACC s Plastics Division mission is to deliver value through exceptional advocacy, political engagement, communications and scientific research ACC s Plastics Division Auto Team activities encourage innovative thinking and promote broader applications for plastics in the automotive industry: Established reputation for technical expertise and educational programs Excellence in advocacy, communications and pre-competitive research Demonstrating plastics and composites are a responsible and sustainable choice over the vehicle life cycle Learn more at: Plastics Division Members:

3 BASF at a Glance Our chemicals are used in almost all industries We combine economic success, social responsibility and environmental protection Sales 2012: 72,129 million EBIT 2012: 6,742 million R&D Expenditures: 1,730 million, automotive 200 million In 2012, BASF filed for around 1,170 new patents worldwide Employees (as of December 31, 2012): 110,782 6 Verbund sites and around 380 production sites 3

4 BASF collaboration / innovation across broad automotive value chain BASF Group Sales 2012 Industry structure BASF products 30% OEM Coatings Coolants & Brake Fluids Plastics for OEMs with own processing Module/ system supplier Tier-1 Plastics Catalysts Coatings for car parts 72 bn BASF Automotive Sales ~ 10 billion 60% Component supplier Tier-2 Plastics Catalysts Coatings for car parts Pigments Parts supplier Tier-3+ Plastics Pigments Solvents 10% Aftermarket Refinish coatings Coolants & Brake Fluids Fuel additives Chemistry for sustainable mobility! 4

5 Weight Reduction is One Important Lever to Reach CO 2 Targets CO 2 reduction levers until 2020 and 2025 (g/km) Ø 141g Ø 46g ? Today Segment effect 20 Combustion engine optimization Weight reduction Electrification Target 2020? Target 2025 Source: BCG Automotive Study

6 Solutions of the Chemical Industry are a Major Lever to Make ICEs More Efficient Fuel additives Reduced deposits and improved combustion High temperature plastics Weight reduction and new functionalities Lubricants and additives Low friction and wear 6

7 Chemical Industry Improves Battery Power and Charge Density Lithium Ion Battery Cathode materials and electrolyte Plastic materials Lightweight housings and connectors Post Lithium Ion Battery materials Higher capacity and battery power 7

8 Current Light Weight Concepts: Weight Percentage of Plastics in Cars Weight distribution of materials in a mid-sized car (1500 kg) kg Steel 700 Light metals 290 Other metals 55 Thermoplastics 190 ca. 20 % polymer Elastomers 50 materials, Thermosets 35 ca. 15 % plastics Thermoplastic elastomers 4 Fluids & Chemicals 80 Glass & Ceramics 40 Textiles & Fabrics 35 Paints & Adhesives 15 Electronics 5 Others 8 Ratio of plastics will increase further to save additional weight 8

9 Up to 100 kg Weight Reduction Achieved by Short Fiber Reinforced Plastics Air intake manifold Seat Charge-air lines Structural inserts Oil pan Front end carrier Lower bumper stiffener Engine mount Cross beam Under the hood Exterior Interior 9

10 Highest Stiffness by Combination of Injection Molding with Press-forming Stiffness by Design/Design Freedom Injection Molding 2 Compression Flow-forming Press-forming 1 Tape-laying Stiffness by Material / Intrinsic Stiffness 10

11 Aerospace is Front Runner in Using Composites as High Performance Material Composite wt% of airframe 60% 50% 50% 53% 40% 30% 20% 10% 10% 0% 1% B747 (1970) A330 (1993) B787 (2010) A350 (2013) Source: MTU, Airbus, Boeing, BCG analysis 11

12 Cost of Composite Automotive Parts Need to be Reduced Along the Value Chain Relative comparison for parts with same function quasi-isotropic CFRP UD % 800 process costs (labor + tools) -40% relative part cost steel 100 high strength steel 135 aluminum % matrix fiber material costs (raw materials + auxiliaries) relative weight steel CFRP 2020 CFRP today 100 Source: RolandBerger, VDMA, 2012, Serienproduktion von hochfesten Faserverbundteilen 12

13 Holistic Approach for Lightweight Needed Multi-material (core or skin first technologies) Liquid composite molding Compression molding Sandwich systems Resin transfer molding (RTM) Liquid impregnation (LI) Pre-Impregnated (Prepreg) Sheets Fiber reinforcement Development status of holistic approach Material Process Design Time to market > 5 years < 1 years 13

14 Holistic Approach for Lightweight Needed Multi-material (core or skin first technologies) Liquid composite molding Compression molding Sandwich systems Resin transfer molding (RTM) Liquid impregnation (LI) Pre-Impregnated (Prepreg) Sheets Fiber reinforcement Development status of holistic approach Material Process Design Time to market > 5 years < 1 years 14

15 Overmolded Thermoplastic Composites Allow Cost Efficient Processes PA thermoplastic laminate (textile or UD tape) Press Insert Ultramid + Opel, BASF Astra OPC seat pan Composite seat part Thermoplastic laminate insert + Ultramid overmolding Faurecia, BASF SUSCO 1.5 concept seat also possible: inmold forming (thermoforming of thermoplastic laminate in injection mold) 15

16 Production of Serial Front Seat Pan (Opel Astra OPC) thermoplastic laminate: IR heating, in-mold forming and overmolding with Ultramid cycle time: 70 s 16

17 Production of Serial Front Seat Pan (Opel Astra OPC) thermoplastic laminate: IR heating, in-mold forming and overmolding with Ultramid cycle time: 70 s 17

18 BASF has Installed a High-Capacity Composite Manufacturing Cell in 2013 Multi-functional test part, developed by BASF 18

19 Holistic Approach for Lightweight Needed Multi-material (core or skin first technologies) Liquid composite molding Compression molding Sandwich systems Resin transfer molding (RTM) Liquid impregnation (LI) Pre-Impregnated (Prepreg) Sheets Fiber reinforcement Development status of holistic approach Material Process Design > 5 years < 1 years 19

20 Holistic Approach for Lightweight Needed Multi-material (core or skin first technologies) Liquid composite molding Compression molding Sandwich systems Resin transfer molding (RTM) Liquid impregnation (LI) Pre-Impregnated (Prepreg) Sheets Fiber reinforcement Development status of holistic approach Material Process Design > 5 years < 1 years 20

21 Sandwich Systems Allow Optimum Light Weight Design Sandwich Concept Material Function coating skin foam core CarboProtect EP, PA, PU PU, PET, XPS, SAN, part. foams UV protection stiffness / strength light foam spacer 21

22 Sandwich Structures Enable Function Integration and Further Weight Reduction Concept comparison Reference: Steel construction Reference: Aluminium construction Generic concept: FRP monolith Generic concept: FRP sandwich Construction Two-piece design: Two-piece design: Two-piece design: Glass fibers Carbon fibers Sandwich structure: Glass fibers Carbon fibers Weight construction Metal skins: 7.6 kg Aluminium skins: 3.6 kg CFRP structure: 6.2 kg CFRP structure: 3.4 kg GFRP structure: 2.8 kg CFRP structure: 1.7 kg Fasteners 0.7 kg Fasteners 0.9 kg Inserts 0.7 kg Inserts 0.7 kg Foam core 1.1 kg Foam core 0.6 kg Inserts 0.7 kg Inserts 0.6 kg Total weight: 8.3 kg 4.5 kg 6.9 kg 4.1 kg 4.6 kg 2.9 kg 22

23 CAE Tool Helps to Optimize the Design of Plastic Parts ULTRASIM Material modelling - Integrative Simulation Anisotropic Nonlinear Strain-rate sensitive Tension-compression asymmetric Failure modeling Calculate the part right CAE Methods + Mathematical Optimization Process simulation Mechanical simulation Mathematical optimization (parameter, shape, topology) Calculate the right part 23

24 Dynamic Modeling Allows Accurate Prediction of Reality Faurecia, BASF SUSCO 1.5 concept seat 24

25 Next Step: Validation of System Solutions in Real Parts BASF co-operations to align fiber and matrix chemistries Fracture limit surface inter fibre fracture Joint assessment in real application projects [Puck 1969] Fracture limit surface fibre fracture Joint project in line with strategy to deliver full benchmarking in application projects 25

26 Gradual Replacement by Continuous Fiber-Reinforced Composites Body today Various steel types Replacement of hang-on parts doors, hatch backs Structural parts floors, pillars, sills, roofs Whole modules and assemblysystems Complete new vehicle concepts Sources: Audi, VW For composite solutions, current phase until 2016 is decisive: Demonstration of part performance cost sustainability benefits vs. metal alternatives 26

27 cars love chemistry 27

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