Composites & automotive mass production: Any convergence ...

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Composites et production automobiles de masse: Convergence d’intérêts ? Vélizy / DQI/DCHM/PMXP/PMD/MVEL Composites & automotive mass production: Any convergence of interests ? Journées techniques "Le 3ème Round des composites" Hôtel Palladia - Toulouse Stéphane JOLY 31 Janvier 2019

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190131-SJolyComposites 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
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
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
Site de mécanique, fonderie
Site d’assemblage
Centre R&D
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
PSA Groupe: …& especially in Europe
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Site de mécanique, fonderie
Site d’assemblage
Centre R&D
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Amérique Latine
175 257
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
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry
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But there are composite materials on this racing car
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry
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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 / day But only few kg of composite materials / vehicle Why that ?
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
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 reduction Battery box Hydrogen tanks
http://www.nuancierds.fr/DT%20toits.htm
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry
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Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
State of the art: SMC materials + compression molding
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Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
State of the art: SMC materials + compression molding
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Glass fiber SMC semi-structural part: Tailgate inner From 2011 up to now
High production capacity: 1 part / mn Affordable material cost: ~3 € / kg Density: From 1,70 up to 1,95 Assembly: gluing, screwing
DS7 tailgate: exploded view
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
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 = 1406kg mBiW = 312kg (+168kg openings)
Strong will to reduce BiW weight
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry
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Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
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, ???
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
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
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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The car volume is an input of the design stage
=> Compare materials at iso volume
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges : Strength comparison
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Glass fiber UD tapes: acceptable performance
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But their cost per volume is more than twice steel cost
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges: Stiffness comparison
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polymers ?

Materials cost in the part: x5 to x10
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges : cost reduction
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polymers
/ ~
Materials cost in the part: x4 to x8
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
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, Tembec Budget : 18 M€ Duration : 2014 - 2019
Objectives : • Low cost carbon fiber < 8€/kg • E=250GPa • σ~2500 MPa
Still a factor 2 to gain
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials cost reduction: Zero material waste
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Usage coefficient on a part must be close to 100%
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
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)
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Dry fibers + resin injection: C-RTM
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• 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 !!!
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry: Composite process
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Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
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
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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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
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Conclusion
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