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Advanced GMT Applications in the Automotive Industry Richard Broo Quadrant Plastic Composites, Inc. Harri Dittmar Quadrant Plastic Composites AG SPE Automotive.

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Presentation on theme: "Advanced GMT Applications in the Automotive Industry Richard Broo Quadrant Plastic Composites, Inc. Harri Dittmar Quadrant Plastic Composites AG SPE Automotive."— Presentation transcript:

1 Advanced GMT Applications in the Automotive Industry Richard Broo Quadrant Plastic Composites, Inc. Harri Dittmar Quadrant Plastic Composites AG SPE Automotive Composites Conference

2  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 Applications

3  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)

4  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) Advanced GMT Applications

5  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)

6 Advanced GMT Applications  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 fabric Glass-Aramide non-crimped PET special weave

7 Advanced GMT Applications  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

8 Advanced GMT Applications  Material Basics: Laminate Design of GMTex  Tailoring of properties by variation of type and number of reinforcing textile layers:

9 Advanced GMT Applications  Production of GMTex: Extruded PP-films Double Belt Press Glass mats Textile reinforcements Advanced GMT GMTex Surface-layer Middle-layer

10 Advanced GMT Applications  Molding of GMTex: Hot air oven Preheated blanks in the mold GMTex blanks Position of fabrics in the molded part Molded part Preheated blank

11  Impact Performance - Lancia Y Door Module Advanced GMT Applications  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

12  Impact Performance - Lancia Y Door Module Advanced GMT Applications  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:

13  Impact Performance - Lancia Y Door Module Advanced GMT Applications 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

14 Advanced GMT Applications GMT 40% @ 400J - Max. Absorption 800 JGMTex 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

15 Advanced GMT Applications GMT 40% @ 400J - Max. Absorption 800 JGMTex 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

16 Advanced GMT Applications GMTex performance is limited by weak fixation points ! Results of side impact tests:

17 Advanced GMT Applications 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 JD-LFT 40% @ 900 J - max. absorption 500 J Crash-Video

18 Advanced GMT Applications 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 JD-LFT 40% @ 900 J - max. absorption 500 J

19 Advanced GMT Applications Results of hip pad impact tests: Brittle failure !

20  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 Advanced GMT Applications

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

22 Advanced GMT Applications  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

23 Advanced GMT Applications  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

24 Advanced GMT Applications  Current Applications: Bad Road ENS: Audi, BMW, DC, Rover Engine Protection Shield Audi C5 GMTex with polyester weave gives extreme wear and impact resistance

25 Advanced GMT Applications  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

26 Advanced GMT Applications  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

27 Advanced GMT Applications  Current Applications: Hatchback Doors (Nissan Murano)

28 Advanced GMT Applications  Current Applications: Hatchback Doors (Nissan Infinity FX45) Designs of Murano and Infinity hatchback doors in steel not feasible

29 Advanced GMT Applications  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

30 Advanced GMT Applications  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

31 Advanced GMT Applications  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

32 Advanced GMT Applications  Future Developments: Motor Supports (Volvo Test Fleet, 20 Taxis at Göteborg) Weight reduction: 31% (14 vs. 20,5 kg) with first prototypes using only random GMT - the use of GMTex will reduce the weight further Longterm creep and fatigue tests performed before driving tests

33 Advanced GMT Applications  Future Developments: Pedestrian Protection Beam (VW: various models) - Cost & weight savings vs. steel and foam - Superior impact properties vs. LFT / IM / ICM

34 Advanced GMT Applications  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

35 Advanced GMT Applications  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


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