DELIVERING THE FUTURE OF COMPOSITE SOLUTIONS COMPOSITE MATERIALS FOR THE AUTOMOTIVE INDUSTRY PRODUCT INFORMATION : AUTOMOTIVE MATERIALS [email protected] www.gurit.com
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DELIVERING THE FUTURE OF COMPOSITE SOLUTIONS
COMPOSITE MATERIALS FOR THE AUTOMOTIVE INDUSTRY
PRODUCT INFORMATION : AUTOMOTIVE MATERIALS
www.gurit.com
1
INTRODUCTION
Gurit is renowned as one of the leading global manufacturers and suppliers of composite materials
and engineering. Gurit’s unique approach integrates structural design, materials science and
process engineering to offer a complete turnkey composite solution.
Gurit offers a combination of innovative, durable, industry-leading composite products with
unrivalled in-house technical expertise, ensuring best-in-class operation wherever it is applied.
The versatility and durability of Gurit’s products and in-depth engineering knowledge means every
project delivers a performance that is finely tuned to individual specifications and needs. Gurit’s
long history of development and innovation has increased part quality and durability while continual
streamlining of processes have improved productivity and reduced costs.
Gurit’s experience in the automotive market has led to the development of a range of composite
materials for the industry and its suppliers, designed for a variety of applications, both structural
and cosmetic. These materials offer class leading performance along with the recognised benefits
of composites; strength, lightness and the ability to fashion complex shapes.
APPLICATION EXAMPLE COMPONENT PROCESS PRODUCT NAME ATTRIBUTE
Interior Visual Carbon
Dashboards, door cards, trim, steering wheels
AutoclavePress
SC 110(T2)White spot free high clarity resin for cosmetic parts
Exterior Visual Carbon
Spoiler, front and rear splitter, door mirror caps, side skirts, exhaust tips, engine covers
AutoclavePress
SC 110(T2)SC 160
High clarity resinOptional higher temperature resistance
Body Panels
Simple geometry:Hoods, roofs
PressSmartcure™SC 160
Rapid cure for high volume manufacturing
Complex geometry:Fenders, boot-lids
Vacuum BagAutoclave
SF 80, SF 80FROBL, SF 95VH, SF 96, SY 100, ST 110
Cost effective body panel system ideal for prototyping and low to medium volume manufacturing
Structural
Chassis components and bulkheads
AutoclavePress
Smartcure™
Rapid curing combined with good thermal and mechanical property retention
Wheels, driveshaftRTMFilament Winding
PRIME™ 180
High clarity combined with good thermal and mechanical property retention
High TemperatureHeat-shields, brake ducts, engine components
Autoclave SE 300Extremely high temperature resistance
GURIT’S RANGE OF PERFORMANCE & STRUCTURAL PREPREGS
32
FORMAT SYSTEM MAIN FEATURESLOWEST CURE FASTEST CURE
TOUGHENEDRECOMMENDED PROCESSING METHOD
Max Tg1 BY DMA
(°C)
SHELF-LIFETYPICAL APPLICATIONS
TYPICAL REINFORCE-MENTS
ANCILLARY PRODUCTS
PAGETEMP
(°c)TIME (HRS)
TEMP (°c)
TIME (MINS)
MTHS @ -18°C
DAYS @ +21°C
HIG
H P
ERFO
RM
AN
CE
Prepreg SC 110(T2)¬ White spot free high clarity resin for cosmetic parts¬ Versatile, high strength prepreg resin system¬ Flexible cure as low as 85°C
85 10 150 20 NoAutoclavePress Moulding
125 18 21Ideal for high visual quality components without white-wash or white spots
CarbonE-Glass
4
Prepreg SC 160 ¬ Class leading resin clarity¬ High temperature performance
130* 1.5 160 15 YesAutoclavePress Moulding
180 18 21Suitable for use in high temperature applications
Carbon 4
Prepreg Smartcure™¬ Rapid cure in less than 5 minutes¬ Ideal for Hot-in Hot-out press moulding manufacture
130 15 150 5 Yes Press Moulding 175 18 42High volume component manufacture
KTL capableCarbon 5
Prepreg SE 300¬ Modified Cyanate Ester resin system¬ High Tg system with good moisture resistance¬ Suitable as a BMI resin substitution
135* 120 180* 60 NoAutoclavePress MouldingVacuum Bagging
300 6 15Structures for high temperature applica-tions such as engine cowlings etc
CarbonE-Glass
5
AN
CIL
LAR
IES
Adhesive Film
SA 80¬ Consistent bond-line thickness and weight¬ High strain to failure, high toughness¬ Handling & no mixing convenience
80 12 120 60 YesAutoclavePress MouldingVacuum Bagging
100 24 56Co-cure with 80°C prepregs for core and high strength adhesive bonding applications
E-Glass 6
Surface Films
SF 80¬ Surface film to generate a resin rich surface¬ Suitable for subsurface applications ¬ Available in different colours
80 12 120 60 YesAutoclavePress MouldingVacuum Bagging
100 24 14Co-cure with 80°C prepregs for resin rich surface
NoneE-Glass
SY 110ST 110
6
SF 96 ¬ Pinhole-free surface for the application of paint systems 85 10 120 60 NoAutoclaveVacuum Bagging
115 24 5Body panels
Prototype, part manufactureE-Glass
SY 110ST 110
7
SF 80FROBL¬ Surface film to generate resin-rich surface¬ Fire retardant
85 10 120 60 NoAutoclaveVacuum Bagging
120 24 14Engine bulkhead
Motor sportE-Glass
SY 110ST 110
7
SF 95VH ¬ Silicon Carbide filled film to generate very hard wearing surfaces 85 10 120 60 YesAutoclavePress MouldingVacuum Bagging
130 24 3Ideal for applications that require a highly toughened system such as car body undertrays
E-GlassSY 110ST 110
8
Syntactic Core
SY 110 ¬ Lightweight, drapable core material¬ Available at 0.7 and 1.0mm thickness
85 10 130 30 No Vacuum Bagging 110 24 56 Produces ultra light and stiff panels None
ST 110SF 96SF 95VHSF 80FROBL
8
PER
FOR
-M
AN
CE
SPRINT ST 110
¬ Drape and tackiness optimised for excellent handling¬ Ideal for complex or vertical mouldings¬ Excellent balance of mechanical performance and toughness
85 10 130 30 NoAutoclaveVacuum Bagging
115 24 14Body and closure panels for automotive applications
CarbonE-Glass
SY 100SF 96SF 95VHSF 80FROBL
9
RTM PRIME™ 180
¬ High Clarity ¬ Low viscosity designed for RTM processes¬ High temperature performance and good surface clarity¬ For structural and aesthetic applications
80* 2 120* 20 Yes RTM 195 18 months @ 21oCWheels
Driveshaft
CarbonE-Glass
9
* Will require post cure to maximise thermal properties, please refer to TDS.
4
HIG
H P
ER
FOR
MA
NC
E P
RE
PR
EG
S
5
SE 300High Temperature
Cyanate Ester Prepreg
¬ Achieves a Tg > 200°C after a cure temperature of 180°C
¬ Can achieve a Tg > 300°C after a post-cure temperature of 300°C
¬ Ideal for components exposed to high temperatures for short durations
¬ Low moisture absorption with high temperature wet performance
¬ Good mechanical properties within large temperature range
¬ Self-extinguishing and low smoke emission
¬ Easy handling and drape-ability (good tack life)
¬ Long shelf and shop life
INTRODUCTIONSE 300 is an ideal prepreg resin for high temperature composite applications, as it combines the ease of processing and handling convenience of epoxy resins, high temperature stability of polyimides, and flame and fire resistance of phenolics.
A 135°C cure for 120 minutes combined with a post-cure, enables SE 300 to generate a Tg in excess of 300°C, making SE 300 ideal for applications in composite structures, which are exposed to very high temperatures for short durations.
TYPICAL APPLICATIONS
Stuctures for high tempertature applications such as engine cowlings.
Very high tem-
perature stability
Long shelf
and shop lifeHigh mechan-
ical properties
SC 110(T2)Cosmetic Carbon Prepreg
¬ Ultra high clarity – ideal for cosmetic components with no white-wash or spots
¬ High-strength prepreg system
¬ Versatile process window with autoclave and press moulding
¬ Curable at temperatures as low as 80°C
¬ Fast 45 min cure at 120°C
¬ Rapid 20 minute cure at 150°C in a press
¬ Excellent tack allowing easy in-mould repositioning
INTRODUCTION
SC 110(T2) is ideally suited to achieve visual surface quality. This cosmetic grade prepreg utilizes a high clarity, versatile, hot-melt epoxy resin formulation. This specifically developed, unique formulation produces truly white-wash-free parts resulting in increased production output and scrap cost savings of up to 20%. SC 110(T2) can be cured at temperatures as low as 80°C or even faster cures are achievable using press moulding technologies at temperatures up to 150°C. QUV SE Accelerated Weathering Test has revealed that Gurit SC 110(T2) carbon prepreg offers superior weathering performance compared with the current market range.
TYPICAL APPLICATIONS
Gurit’s SC 110(T2) is suitable for automotive applications where a high clarity finish is required.
45 min cure
at 120°CUltra high
clarity
SC 160Cosmetic Carbon Prepreg
¬ Ultra-high clarity prepreg system
¬ Ideal for visual components
¬ Autoclave cure offers 180°C (356°F) Tg
¬ Rapid press moulding
¬ Curable at temperatures as low as 130°C (266°F)
¬ High tack and drape allowing easy in-mould repositioning
INTRODUCTION
SC 160 is a visual grade prepreg that utilises a high clarity, versatile, hot-melt epoxy resin formulation.
The unique formulation is ideal for manufacturing visual quality components using autoclave and press moulding. It can be cured at temperatures as low as 130°C (266°F), or it can be used for rapid press moulding of components at 160°C (320°F). A maximum resin Tg of 180°C (356°F) can be achieved from an autoclave cure. The product has high tack which aids the moulding of complex components in metal and carbon tooling, whilst maintaining a good out-life of up to 3 weeks at 21°C (70°F). SC 160 is a toughened system and offers excellent mechanical properties on a wide variety of reinforcing fabrics and fibres.
TYPICAL APPLICATIONS
SC 160 is suitable for interior and exterior automotive applications where a high clarity finish is required in conjunction with a high Tg.
15 min cure
at 160°CUltra high
clarity
Smartcure™5 minute Curing Prepreg
¬ Epoxy Prepreg Optimised for Press Moulding Applications
¬ Developed for Automotive Component Production
¬ Good Surface Finish
¬ Net Shape Components
¬ Hot-in, Hot-out Press Processing
¬ 5 Minute Cure Time at 150°C
INTRODUCTIONSmartcure™ Prepreg has been specifically developed for high volume press moulding applications and enables users to perform cycle times of 5 minutes.
The products characteristics facilitate simple preforming prior to moulding and the ability to fill edged detail during moulding, allowing net shaped parts to be manufactured.
TYPICAL APPLICATIONS
High volume component manufacture. KTL capable.
5 minute cure time @ 150oC
Developed for
automotive
6
AD
HE
SIV
ES
FIL
MS
UR
FAC
E F
ILM
7
SF 80FROBLFire Retardant Surfacing Film
¬ Provides an effective fire retarding layer to epoxy substrates
¬ With the correct tooling can provide a high gloss black surface finish
¬ Resistant to moisture ingress
INTRODUCTION
SF 80FROBL surfacing material is a Fire Retardant Obliterated Black (FROBL), filled epoxy film. It provides an effective fire retarding layer capable of withstanding exposure to fire, while preventing the epoxy substrate from combustion.
SF 80FROBL can be used directly against a suitably release treated mould surface, with prepreg or SPRINT™ plies laid up behind it, or as a final layer in the mould. The product is sufficiently tacky to aid placement into vertical surfaces of a mould. SF 80FROBL can be cured with vacuum only processing.
The epoxy system is applied to a supporting medium and ready catalysed, requiring only a moderate temperature cure.
TYPICAL APPLICATIONS
Typical applications include protection of structural components in high risk areas such as engine bays, exhaust runs, and around the fuel system.
Surface film to
generate a resin
rich surface
Excellent FST
propertiesSF 80Toughened Surfacing Film
¬ Toughened System
¬ Protects underlying laminate
¬ Reduction in surface film-laminate interfacial voids
¬ Improved resistance to water ingress
¬ Suitable for post painting
INTRODUCTION
SF 80 surfacing material is a light green, toughened, epoxy film designed to enhance the surface finish of moulded composite components. It allows a good surface finish to be obtained by vacuum-bag moulding processes. It can be used directly against a suitably release treated mould surface, with prepreg or SPRINT™ plies laid up behind it. When fully cured with SPRINT™ or prepreg, SF 80 forms a stable tough surface which can be sanded in preparation for painting. The epoxy system is applied to a supporting medium and ready catalysed, requiring only a moderate temperature cure.
TYPICAL APPLICATIONS
Co-cure with 80-120°C prepregs for resin rich surface.
Surface film to
generate a resin
rich surface
80oC cure temperature
SA 80Toughened Epoxy
Film Adhesive
¬ Low temperature cure
¬ Designed for bonding prepreg skins to honeycomb and certain foam cores
¬ Controlled flow for maximum bond integrity
¬ Toughened for impact resistance and peel strength
INTRODUCTION
SA 80 is a film adhesive that is designed for secondary bonding, core-bonding and for co-curing with the range of Gurit prepregs. It can be cured at temperatures as low as 80°C, or can be more quickly cured at temperatures above 120°C. It has an out-life of 56 days at room temperature.
TYPICAL APPLICATIONS
Suitable for bonding aluminium, foam and honeycomb cores in conjunction with Gurit’s range of Prepreg or Ampreg laminating sys-tems. See individual Technical Datasheets for further information.
PACK SIZES & AVAILABILITY
SA 80 is available in weights up to 300g resin films with or without* a glass carrier.
*150 and 250g only
Ideal for
core bonding
High
toughness80oC cure temperature
SF 96Sandable Surfacing Film
¬ Easy to sand ¬ Significant reduction in print-through
¬ Reduction in surface film-laminate interfacial voids ¬ Improved opacity
¬ Improved resistance to water ingress ¬ Stable surface up to 115°C (depending on cure)
INTRODUCTION
SF 96 surfacing material is an epoxy film designed to enhance the surface finish of moulded composite components. It allows a good surface finish to be obtained by vacuum-bag moulding processes. It can be used directly against a suitably release treated mould surface, with prepreg or SPRINT™ plies laid up behind it. When fully cured with SPRINT™ or prepreg, SF 96 forms a stable sandable surface which, once lightly sanded to provide a key for painting, provides a pin-hole free laminate. The epoxy system is supplied ready impregnated into a supporting medium and ready catalysed, requiring only a moderate temperature cure.
TYPICAL APPLICATIONS
Co-cure with 85°C prepregs for resin rich surface ideal for sanding / priming prior to painting.
Stable surface
up to 115oCPinhole Free surface
Surface film to generate a resin rich surface
85oC cure temperature
8
SF 95VHAbrasion-Resistant Surfacing Film
¬ Hard protective coating
¬ Increases surface longevity by up to 300%
¬ Reduction in surface film laminate interfacial voids
¬ Improved opacity
INTRODUCTION
SF 95VH surfacing material is a very hard, abrasion-resistant epoxy film. It is designed to protect vulnerable underbody components from damage caused by foreign objects. Typical applications include inner wings, and front wheel diffusers. SF 95VH can be used directly against a suitably release treated mould surface, with prepreg or SPRINT™ plies laid up behind it, or as a final layer in the mould. It can be cured with vacuum only processing. Due to abrasion-resistance of this material, it would not be usual to apply a paint finish. The epoxy system is supplied ready impregnated into a supporting medium and ready catalysed, requiring only a moderate temperature cure.
TYPICAL APPLICATIONS
Ideal for applications that require a highly toughened system such as car body undertrays.
Hard protective
coatingAbrasion
resistant
PRIME™ 180High Tg RTM System
¬ Low viscosity designed for RTM processes ¬ Long pot-life and wide injection window
¬ De-mouldable after 20 min at 120°C ¬ High Tg (>190°C) following cure at 180°C
¬ High temperature performance and good surface clarity
¬ For structural and aesthetic applications
INTRODUCTION
PRIME™ 180 is a two-component toughened epoxy system formulated for RTM processes for manufacturing high quality structural carbon components.
PRIME™ 180 has a low mixed viscosity at room temperature and versatile curing, this allows for low temperature injection which can then be followed by a pre-cure between 80-120°C. The resin has low viscosity and a long injection window at low-medium temperatures which allows complex or thick section laminates to be manufactured.
TYPICAL APPLICATIONS
Ideal for applications that require a highly toughened system such as car body undertrays, wheels, driveshafts and engine covers.
High temperatureperformance
De-mouldable after 20 min at 120°C
RTM
9
ST 110Car Body Panel System
SPRINT™ Resin
¬ Drape and thickness optimised for excellent handling
¬ Ideal for complex or vertical mouldings
¬ Excellent balance of mechanical performance and toughness
¬ Suitable for autoclave and vacuum bag processing
INTRODUCTION
ST 110 is used alongside a suitable surfacing film (SF 80, SF 80FROBL or SF96) and SY110 Syntactic Core to build up a CBS panel. The woven carbon and glass reinforcements can be used to lay up various panel combinations to suit the required stiffness and weight targets needed.
TYPICAL APPLICATIONS
Structural ST 110 is used to form a multi layered material referred to as CBS Car Body SPRINT™ for body and closure panels for automotive applications.
Good balance
of mechanical
properties
PE
RFO
RM
AN
CE
PR
EP
RE
GS
SY
NTA
CTI
C C
OR
E
SY 110Low Density Syntactic Core
¬ Lightweight drapable core material ¬ Co-curable with all Gurit Prepregs & SPRINT™
¬ Produces ultra-light and stiff panels ¬ Fast lay-up times
¬ Wide process window; curing from 85-130ºC (185-266ºF)
¬ Available at 0.7mm and 1.0mm thickness
INTRODUCTION
SY 110 is a lightweight, drapable core material that is designed to be co-curable with most Gurit Epoxy Prepreg and SPRINT™ materials, to produce ultra-light and stiff panels
Curing from 85oC - 130oC
Fast lay-uptimes
SPRINT™
Technology
Auto Materials Bro-11-0218
Customer Support Composite Materials
EMEA
Gurit (UK) Ltd
St Cross Business Park
Newport, Isle of Wight,
PO30 5WU United Kingdom
T +44 1983 828 000
F +44 1983 828 100
www.gurit.com
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