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

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

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)

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: 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 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)

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

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

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

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

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

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

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:

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

Advanced GMT Applications Comparison of energy absorption and failure behavior at side impact test STAMAX 40% @400J - Absorption 120 J D-LFT 40% @400J - Absorption 250 J Crash-Video Crash-Video GMT 40% @ 400J - Max. Absorption 800 J GMTex ML @1000J - Absorption 1000 J Crash-Video Crash-Video

Advanced GMT Applications Comparison of energy absorption and failure behavior at side impact test STAMAX 40% @400J - Absorption 120 J D-LFT 40% @400J - Absorption 250 J GMT 40% @ 400J - Max. Absorption 800 J GMTex ML @1000J - Absorption 1000 J

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

Advanced GMT Applications Comparison of energy absorption and failure behavior at hip pad impact test STAMAX 40% @ 900 J - max. absorption 450 J D-LFT 40% @ 900 J - max. absorption 500 J Crash-Video Crash-Video GMT 40% @ 1200 J - max. absorption 900 J GMTex TL +/-45° @ 1440 J - max. absorption 1300 J Crash-Video Crash-Video

Advanced GMT Applications Comparison of energy absorption and failure behavior at hip pad impact test STAMAX 40% @ 900 J - max. absorption 450 J D-LFT 40% @ 900 J - max. absorption 500 J GMT 40% @ 1200 J - max. absorption 900 J GMTex TL +/-45° @ 1440 J - max. absorption 1300 J

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

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

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)

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

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

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

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

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

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

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

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

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

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

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

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

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

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