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. Advanced GMT Applications
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

3. Advanced GMT Applications
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. Advanced GMT Applications
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: 2 mm wall thickness)
Low tooling costs compared to steel stamping tools (better efficiency for cars with low production numbers: < cars per year)

5. Advanced GMT Applications
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
PET special weave
Glass-Aramide
non-crimped
Glass fabric

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:
E-Modulus of PP-GM40
15000 0°
45°
90°
135°
180°
225°
270°
315° 0°
15000
315°
45°
270°
90°
225°
135°
180°
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
GMTex 
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile reinforcements
Surface-layer
Double Belt Press

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

11. Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
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

12. Advanced GMT Applications
Impact Performance - Lancia Y Door Module
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. Advanced GMT Applications
Impact Performance - Lancia Y Door Module
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
Comparison of energy absorption and failure behavior at side impact test
STAMAX - Absorption 120 J
D-LFT - Absorption 250 J
Crash-Video
Crash-Video
GMT 400J - Max. Absorption 800 J
GMTex - Absorption 1000 J
Crash-Video
Crash-Video

15. Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX - Absorption 120 J
D-LFT - Absorption 250 J
GMT 400J - Max. Absorption 800 J
GMTex - Absorption 1000 J

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

17. Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 900 J - max. absorption 450 J
D-LFT 900 J - max. absorption 500 J
Crash-Video
Crash-Video
GMT 1200 J - max. absorption 900 J
GMTex TL 1440 J - max. absorption 1300 J
Crash-Video
Crash-Video

18. Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 900 J - max. absorption 450 J
D-LFT 900 J - max. absorption 500 J
GMT 1200 J - max. absorption 900 J
GMTex TL 1440 J - max. absorption 1300 J

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

20. Advanced GMT Applications
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

21. Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1 Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Part weight: 3,2 - 3,5 kg
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)

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
Part weights: 1,1 / 1,3 kg
Molder: Polynorm UK

23. Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and VW Touareg)
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
Molder: Rangerplast Italy

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

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)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets

30. Advanced GMT Applications
Current Applications: Rear Axle Support (All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum

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