High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets...

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High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets Under the Hood Jim Cederstrom Automotive Business Development Manager Bulk Molding Compounds, Inc Sept 16, 2009 SPE – Automotive Composites Conference & Exhibition

Transcript of High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets...

Page 1: High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets Under the Hood Jim Cederstrom Automotive Business.

High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets Under the Hood

Jim CederstromAutomotive Business Development ManagerBulk Molding Compounds, IncSept 16, 2009SPE – Automotive Composites Conference & Exhibition

Page 2: High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets Under the Hood Jim Cederstrom Automotive Business.

Past Drivers for Plastics (Vehicle Weight Gain)

*Source: U.S. Environmental Protection Agency, Light-Duty Automotive Technology and Fuel Economy Trends: 1975 Through 2008

Lbs

Mar

ket S

hare

(%)

Page 3: High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets Under the Hood Jim Cederstrom Automotive Business.

• Consumer Preference– High displacement engines (Fun to Drive)– 4 wheel drives– Advanced climate control systems– NVH improvements – Infotainment systems

• Advanced Safety Systems– Anti-lock brakes, Stability/Traction Control,

Airbags

• Emissions Systems– Fed Tier II and CARB LEV requirements

• Negative impact on cost/weight/CAFE

Past Drivers for Plastics (Vehicle Weight Gain)

Page 4: High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets Under the Hood Jim Cederstrom Automotive Business.

• 331 lbs of Plastics/Composites• More than 30% increase• Average 150 lbs vehicle weight

reduction• UTH last to grow

*Source: American Chemistry Council

Plastics Growth in Vehicles(Weight reduction)

• 250 lbs of Plastics/Composites

Page 5: High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets Under the Hood Jim Cederstrom Automotive Business.

Typical Application Requirements

• Temperature Resistance: -40C to 130C• Chemical Resistance:

– Coolant, Brake Fluid, Fuels, Solvents, NaCl, Humidity, Hot Engine Oil

• Vibration/Impact Resistant• Structural Rigidity• Creep Resistance• Long Term Dimensional Stability

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Progression of Plastics Under the Hood

1985 1995 2005

Lbs of Plastic

PP, PA66, PBT BMC, SMC, PA66, PA6, PA66 PPA, PPS, PA4,6, BMC,

Phenolic

9 lbs

18 lbs

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What’s Next for Composites Under the Hood?(Market Drivers)

• Dramatically increased emissions and fuel economy regulations– US CAFE - 35 mpg– US Emissions Fed Tier 2 and

CARB LEVII (CO2, NOx)– EURO 5 and EURO 6 Emissions

• Rising fuel prices• Extended warranties• Consumer sentiment towards

greener vehicles• Drive toward energy

independence

• Vehicle Downsizing• Engine Downsizing• More Efficient Powertrains• Complex Powertrain Controls• Alternative Fuels/Energy

• More extreme requirements• Renewed and aggressive focus

on lightweight materials and cost reductions

MARKET DRIVERS RESULT

Page 8: High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets Under the Hood Jim Cederstrom Automotive Business.

New and more demanding applications

• GDI and diesel engines• Turbo/super charging• Highly active intake systems• Electronically controlled valve

actuation/timing• Drive by wire systems• Cylinder deactivation• EGR• Alternative/bio fuels• Engine start/stop systems• Hybrid Electric Powertrains

• More complex systems• Tighter packaging space• Higher heat• Higher pressures• More corrosive fluids• Added Cost

“Higher Performance Polymers”• Existing composite apps• New hydraulic/mechatronic systems

TECHNOLGY TRENDS RESULT

Page 9: High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets Under the Hood Jim Cederstrom Automotive Business.

Future Growth in Plastics Under the Hood(New Requirements for PT Composites)

• Higher Temperature Resistance: -40C to 150C (>200C)• Mechanical Strength and Impact Resistance Across a Wider Range

of Temperatures• Chemical Resistance (New more aggressive fluids):

– Long Life Engine Coolants: OAT, HOAT– Alternative fuels: Flex fuels, Diesel Fuel, BioDiesel Fuels– EGR gases

• Long Term Dimensional Stability– Tighter tolerance requirements– Across wider temperature range

• Creep Resistance (high temp)• Longer Warranty Periods

Page 10: High Value Metal Replacement in Automotive Powertrain Applications New Opportunities with Thermosets Under the Hood Jim Cederstrom Automotive Business.

• Long history of BMC composites in demanding automotive applications

• More than 90% of all automotive headlamp reflectors are produced in BMC

• Very high temperature resistance, high precision parts, low system cost.

Bulk Molding Compound (BMC) Composite Materials

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BMC Composite Material Composition(Wide Range of Materials/Properties)

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Composite Cost Comparison

On a cost / unit volume basis thermosets offer significantly higher value compared to many High Performance Thermoplastics.

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Phenolic

VE-BMC

PP

PA66, 6, PBT, PET

PPA, PA4,6

PPS

PEI

LCP, PEEK

PRICE

PER

FOR

MA

NC

E

Thermosets offer a much higher Performance vs.

Price ratio

PE-BMC

BMC vs. High Performance Thermoplastics

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BMC vs. High Performance Materials

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Material Mold Shrinkage

(%)

CLTE (μm/m°C) RT

to 150°C

Moisture Absorption

(%)

Aluminum 0.70 20 0

BMC Dimension X

0.00 18 0.15

PPS (50% GF) 0.33 58 0.03

PEI (30% GF) 0.30 48 0.25

PA6,6 (30% GF) 0.25 61 >1.0

BMC Precision Net Shape MoldingBMC composites provide the tightest tolerance and dimensional stability over any other high performance composite material

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• Normally lower shrinkage BMC’s result in higher CTLE, and less compressive creep resistance

• Optimization of the low profile additives, resin cross-linking density, filler system, and fiber have resulted in a new BMC composite systems that provide the maximum creep resistance, lowest possible CTLE and smallest possible molded part tolerances

• These breakthroughs can now being translated in to various high precision powertrain applications.

Key Factors Driving Dimensional Improvements in BMC

Intake Systems TransmissionSystems

Pump Housings

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Dimensional Change (%) After Exposure to Various Automotive Fluids (2000 hours)

BMC Dimensional Change/Fluid Exposure

Fluid BMC Composite (% dim change)

Dexcool (93°C) 0.05

Used Engine Oil (150°C) 0.00

ATF (150°C) 0.01

Gasoline (24°C) 0.03

Power Steering Fluid (150°C) 0.01

Brake Fluid (150°C) 0.14

• Part dimensions can also be affected by the absorption of various automotive fluids.

• BMC demonstrate very low dimensional change to most automotive fluids.

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• BMC Dimension X Polyester Composite

• Cost savings: 20 - 35%• Weight savings: 25-30% (≈ 0.5lb)

• Zero mold shrinkage• Tight/repeatable tolerances

– +0.03/-0.06mm, 90mm bore– +/- 0.015 MM ,20mm bore

• Reduced manifold dynamic loading• Improved icing / no heating• Possible electric motor down sizing• Improves safety during crash

BMC Electronic Throttle Valves

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• BMC 665, 675, 695

• Excellent Track Record– >60 MM parts w/o failure

• Strong/Rigid Parts at High Temps• Excellent Flatness/Tolerances

– Excellent Creep Resistance

BMC in Engine Oil Applications(Engine Sealing)

Engine front/timing covers Pressurized Engine Lubrication Circuit

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BMC Thermal Mechanical Performance

Material Tg (°C) Flexural Modulus 23°C (GPa)

Flexural Strength 23°C

(Mpa)

Aluminum 68.9

BMC Composite 200 13.2 154

PPA (33% GF) 125 10 200

PPS (40% GF) 90 11.1 225

PA 6,6 (33% GF) 55 6.4 180

BMC composites offer very high glass transition temperatures and exceptional stiffness enabling metal replacement in dimensionally critical applications with constant mechanical loading under long term high temperature exposure

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Rigidity at Elevated Temperature(BMC vs. Engineering Thermoplastics)

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• BMC TDV584, BMC 665, BMC 695

• Piece price savings: 30-50%• Weight savings: 25-30%

– 0.25 -1 lb

• Strong/rigid material at high temps (150°C)• Withstands high oil pressure/cycling

– > 15bar– Low deflection

• Self lubricating formulation for low wear• Tight/repeatable print tolerances• Very low creep/CTE

BMC High Pressure Engine Oil Applications(Oil Pump and Filter Housings)

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120°C 2000hr Long Life Coolant Exposure

150°C 2000hr ATF Exposure

BMC Property Retention vs. Fluid Aging150°C 2000hr Engine Oil Exposure

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• Electric engine oil pumps• Electric auxiliary CVT pumps• Electric/auxiliary coolant pumps

– ICE thermal efficiency control– Charge-air cooling – Battery cooling for electric vehicles – Electronics cooling for electric vehicles

• Vacuum pumps for braking • Electric fuel pump inlet/outlet

BMC Pump Applications(Electric Pump Housings)

BMC TDV584, BMC 665, BMC 695

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• Higher engine compartment temps >150°C • BMC low cost/high temp solution for

covers/heat shields• Continuous use temps > 220°C• Low S.G. 1.5-1.6• Class A surface• Excellent flatness• Low thermal conductivity

– 0.5 W/mK

• Easily painted, colored, coated• Inherently flame retardant

BMC High Temperature Exposure(Engine Covers/Heat Shields)

200°C 2000hr Air Exposure

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• Low cost/high performance material solution for proton exchange membrane (PEM) “Bi-Polar” plates

• Excellent balance of conductivity, moldability and physical properties

• Excellent resistance to aggressive fuel cell stack environment

• Very flat and dimensionally stable plates• Very thin plates to 1mm (web thickness as low as

0.3mm)• Innovative conductive adhesive/sealant for anode-

cathode bonding – 50% stack height reduction

• Successful Automotive OEM Pilot Programs

BMC Alternative Powertrain Systems(Hydrogen Fuel Cell)

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• Long history high voltage applications• High Dielectric Strengths (>15 kv/mm)• High UL Relative Temp. Index (RTI) rating (160˚C)• High volume resistivity retention with humidity

exposure (1E+14 Ωcm)• High Comparative Tracking Index to prevent

carbon tracking (>600 Volts )• Inherently flame resistant (UL-94-HB/V0)• Low CTE – Excellent for overmolding and

insulating metal components

BMC Alternative Powertrain Systems(Electric Vehicles)

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• Power distribution module boxes • Inverter/converter boxes/frames• Battery pack frames• Thermal management system components• Overmolded electrical lead frames/bus bars• High voltage connectors • Low cost/high temp solution for heat

shielding/thermal barriers

BMC Alternative Powertrain Systems(Hybrid Electric Vehicles)

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• Molding parts to the correct dimensions, with very tight tolerances, and a wide processing window, has never been easier than with BMC.

• BMC composites maintain tighter print tolerances out of mold and at elevated temperatures as compared to higher cost high performance thermoplastics...and are highly suited for metal replacement in powertrain applications

• BMC thermosets offer the most cost-effective performance at elevated temperatures under load, pressure, and chemical exposure in automotive applications compared to metal and engineered thermoplastics.

• BMC materials are suited for metal replacement in hybrid vehicle powertrains, from highly conductive solutions to high dielectrics

Summary