Composites & automotive mass production: Any convergence ...

Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL

Composites & automotive mass production: Any converge nce of interests ?

Journées techniques "Le 3ème Round des composites"

Hôtel Palladia - Toulouse

Stéphane JOLY 31 Janvier 2019


PSA Groupe: 6 Brands = Citroën, DS, Opel, Peugeot, Vauxhall & Free 2 Move

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Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL 3

PSA Groupe: Production sites: Near our customers worldwide

Site de production automobile

(en joint-venture, en coopération ou partenariat)

Site de mécanique, fonderie


Site d’assemblage

Centre R&D

Centre de pilotage et d’expertises


PSA Groupe: …& especially in Europe

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Site de production automobile


Site de mécanique, fonderie


Site d’assemblage

Centre R&D

Centre de pilotage et d’expertises


Amérique Latine

175 257

-15,0%

Europe

3 106 160

+30,6%

Moyen-Orient Afrique

291 998

-52,8%

Eurasie

15 288

+0,50%

IndePacifique

26 479

+1,6%

ChineAsie du Sud Est

262 583

-32,2%

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PSA Groupe: 2018, commercial results - 3 877 765 vehicles sold dans les 6 régions du Groupe

+6,8% 3 877 765


Composite materials in the automotive industry

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This is not what we call industry

But there are composite materials on this racing car



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This is what we call industry

3,9M vehicles / year⇒ 13 000 vehicles / day (300 days /year)⇒ 18 000 tons of materials / dayBut only few kg of composite materials / vehicleWhy that ?


Composite materials in PSA Groupe: Our present needs

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What are the needs for composite materials introduction on our cars ?

Body in white weight reductionBattery boxHydrogen tanks

http://www.nuancierds.fr/DT%20toits.htm



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What are those composite materials ?


State of the art: SMC materials + compression molding

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1982: Citroën BX


State of the art: SMC materials + compression molding

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Glass fiber SMC semi-structural part: Tailgate innerFrom 2011 up to now

High production capacity: 1 part / mnAffordable material cost: ~3 € / kgDensity: From 1,70 up to 1,95Assembly: gluing, screwing

DS7 tailgate: exploded view


Composite materials in PSA Groupe

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Body in White (BiW), composite part:Glass fiber SMC spare wheel well

Peugeot 3008 1.2 Pure Tech (2016):m = 1406kgmBiW = 312kg (+168kg openings)

Strong will to reduce BiW weight



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No carbon fiber

composite materials ?


Composite materials in the automotive industry: BMW Corner stones

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2016: Serie 7, mainly steel2013: i3, mainly carbon reinforced polymers

2019: i5, ???


Composite materials in the automotive industry: Volvo Polestar 1 (2019)

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Composite parts:• Rear tablet• Rear floor• Tunnel reinforcement• Under seats, rear beam

Not so much and let’s confirm on the car in the street


Composite materials in automotive industry: Major challenges

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What are the major challenges ?



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The car volume is an input of the design stage

=> Compare materials at iso volume


Composite materials in automotive industry: Major challenges : Strength comparison

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Carbon fibers semi-products overpass steel strength

��/��~��

2

Glass fiber UD tapes: acceptable performance

Glass fiber fabrics reinforced polymers show between half and 1/3 of steel strength

��/ � � ��

But their cost per volume is more than twice steel cost


Composite materials in automotive industry: Major challenges: Stiffness comparison

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Introduction of continuous glass fiber reinforced

polymers ?

• Glass composite vs Steel • At iso-volume• Materials are at iso-cost

��

10� ��/��

��

5

But stiffness divided by 5 to 10

Materials cost in the part: x5 to x10


Composite materials in automotive industry: Major challenges : cost reduction

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Introduction of continuous carbon fiber reinforced

polymers

• Carbon composite vs Steel • At iso-volume• Cost is increased by 2 to 4

��/ �~��

2

Stiffness is divided by 2=>

Materials cost in the part: x4 to x8



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The major challenge is raw materials cost reduction


Composite materials cost reduction: FORCE Project

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Sept. 2018: Pilote line available• Mesh size 12K * 10• Production capacity: 2 tons /year• Temperature max: 1150°C

Partners : IRT Jules Verne, CANOE, Groupe PSA, Arkema, Mersen, Plastic Omnium, Chomarat, Renault, Decathlon, Total, Faurecia, Stelia Composites, TembecBudget : 18 M€Duration : 2014 - 2019

Objectives :• Low cost carbon fiber < 8€/kg• E=250GPa• σ~2500 MPa

Still a factor 2 to gain


Composite materials cost reduction: Zero material waste

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Objective: zeromaterial waste

Usage coefficient on a part must be close to 100%



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Major challenge: Production capacity, cycle time


Composite materials in automotive industry: Organosheets + compression molding + overmolding

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COMPOSTAMP project: Complex & large part:- ribs (on both sides)- a tunnel- embossed areas- Overmolding- m = 1915 g, S = 530 x 850 cm²

Cycle time: 1 part every 63 seconds=> Materials and process are ready for mass product ion (material cost too high > 6€/kg)


Composite materials in automotive industry: Dry fibers + resin injection: C-RTM

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Fast RTM project demonstrated:• a material availability

• Arkema Acrylic resin• Hexion Epoxy resin

• an injection process robustness• cycle time of 2 mn / part

⇒ Fast FORM project(2016 – 2021)

It has also demonstrated that preparing a preform in 2mn / preform

is not possible today !!!


Composite materials in the automotive industry: Composite process

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Filament winding

Dry plies preforming (*)

Fiber

length

(mm)

0.5 to 20

25 to 50

Endless

1 2 5

Compression

molding

Injection

molding

Thermo

stamping

C-RTM RTM-TP

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LP-RTMHP-RTM

Automated Fiber/Tape Placement

Fiber

projection

Autoclave

Cycle time

(mn)

Part

complexity

Structural applications

Legend:

C-RTM, HP-

RTM, LP-RTM,

RTM-TP:

Compression,

High Pressure,

Low Pressure,

Thermo

Plastique,

Resin

Transfer

Molding

TP & TS

TSTP



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Major challenge: Multi-materials assembling


Composite materials in automotive industry: Major challenges : Multi-materials assembling

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Assembling steel, aluminum and composite materials with the same tool: electrical welding point

Technology validation on-going



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Other challenges

Composite materials agings: 15 years, 250 000 km- Test standards to define

Composite materials repairing- Protocole to define- Know how to spread


Conclusion

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Long is the road

Thank you for your attention

Composites & automotive mass production: Any convergence ...

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