Advanced GMT Applications in the Automotive Industry Richard Broo Quadrant Plastic Composites, Inc. Harri Dittmar Quadrant Plastic Composites AG SPE Automotive Composites Conference
Apr 01, 2015
Advanced GMT Applications in the Automotive Industry
Richard BrooQuadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
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 ApplicationsAdvanced GMT Applications
Advanced GMT ApplicationsAdvanced 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)
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 ApplicationsAdvanced GMT Applications
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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 ApplicationsAdvanced 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 fabricGlass-Aramide non-crimped
PET special weave
Advanced GMT ApplicationsAdvanced 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
Advanced GMT ApplicationsAdvanced GMT Applications Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of reinforcing textile layers:
0
10000
20000
30000
40000
50000
GMT 40% GF
UD-GMT 40% GF
UD-GMTex 60% GF
UD-GMCTex 30% GF-20%
CF
Ten
sile
stif
fnes
s (M
Pa)
Advanced GMT ApplicationsAdvanced GMT Applications
Production of GMTex:
Extruded PP-films
Double Belt Press
Glass mats
Textile reinforcements
Advanced GMTGMTex
Surface-layer
Middle-layer
Advanced GMT ApplicationsAdvanced 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
Impact Performance - Lancia Y Door Module
Advanced GMT ApplicationsAdvanced 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
Impact Performance - Lancia Y Door Module
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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:
Impact Performance - Lancia Y Door Module
Advanced GMT ApplicationsAdvanced 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
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GMT 40% @ 400J - Max. Absorption 800 J GMTex 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 Crash-Video
Crash-Video Crash-Video
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GMT 40% @ 400J - Max. Absorption 800 J GMTex 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
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Side impact energy absorption
0
200
400
600
800
1000
1200
Stamax 40% D-LFT 40% GMT 30% GMT 40% GMTex ML
J Side impact
GMTex performance is limited by weak fixation points !
Results of side impact tests:
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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 J D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video Crash-Video
Crash-Video Crash-Video
Advanced GMT ApplicationsAdvanced 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 J D-LFT 40% @ 900 J - max. absorption 500 J
Advanced GMT ApplicationsAdvanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
0
200
400
600
800
1000
1200
1400
Stamax40%
D-LFT 40% GMT 30% GMT 40% GMTex ML
J
Hip pad impact
Brittle failure !
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 ApplicationsAdvanced GMT Applications
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 ApplicationsAdvanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1 Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
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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
Advanced GMT ApplicationsAdvanced 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
Advanced GMT ApplicationsAdvanced GMT Applications Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
Engine Protection Shield Audi C5
GMTex with polyester weavegives extreme wear and
impact resistance
Advanced GMT ApplicationsAdvanced 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 ApplicationsAdvanced 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
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Current Applications: Hatchback Doors (Nissan Murano)
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Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano and Infinity hatchback doors in steel not feasible
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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
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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
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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
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Future Developments: Motor Supports (Volvo Test Fleet, 20 Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) withfirst prototypes using only random GMT -the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
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Future Developments: Pedestrian Protection Beam (VW: various models)
- Cost & weight savings vs. steel and foam - Superior impact properties vs. LFT / IM / ICM
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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
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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