Raising performance in automotive composites - Highlight

Advanced Materials

Raising performance and productivity in automotive composites

Quarter 1, 2014

Advanced Materials 2

Table of contents

Huntsman expertise and solutions Pioneer in composite mass production

Composites in automotive Composites applications in automotive

Improving performance

Improving properties

Liquid composites processes in automotive

Pioneer in standard RTM RTM process

Araldite® solutions for standard RTM

Case stories

Mass production solutions Standard pressure vs. high pressure RTM

Wet compression molding process

Araldite® solutions for mass production

Advanced Materials

Huntsman expertise and solutions

First supplier qualified for mass production of carbon composites §  1990 - 2010 : Pioneer in structural composites (monocoque chassis Lamborghini, McLaren, Mercedes SLR, BMW Z1) §  2013 : BMW «i» structural composite parts

Part production efficiency §  Fast and adjustable epoxy systems §  Designed for HP-RTM and compression molding, with fast demolding stiffness development §  Compatible preforming solutions §  Simulation capability

Superior properties §  High elongation at break §  High stiffness

Sustainable footprint §  Bio-based feedstocks utilization §  Best-in-class energy management

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< Table of content Automotive composites > Mass production > Pioneer in RTM > Huntsman expertise >


Composites applications in automotive

Drive shafts

Automotive composites > Mass production > Pioneer in RTM > Huntsman expertise > < Table of content



Leaf springs




Trunk panel (EES technology)




Roof




Indoor panel (EES technology)




Chassis




Wheels




Bonnet




Pressure vessel



Composites applications in automotive Automotive composites > Mass production > Pioneer in RTM > Huntsman expertise > < Table of content


Composites for improved performance

Safety Demonstrated in F1 vehicles

Design Reduction in number of parts (integrated functions)

Aesthetic Impact of visual carbon surfaces

Weight Lower emissions

Lower fuel consumption

Higher pay loads for trucking industry

Noise Absorption

Health No emissions

Life cycle No corrosion



Composites for improved properties

Density in g/cm3




Modulus in MPa




Tensile strength in MPa



Liquid composites processes in automotive

Complexity vs. production speed



Main features and benefits §  Design freedom §  Short cycle time §  Industrial process for medium volume car

part production §  High quality – reproducibility §  Integrated function (eg. number of parts

reduction, metallic insert integration…)

RTM process

RTM principle

View the process video




Araldite® epoxy systems selection(1) for standard RTM Product Mix viscosity Curing temperature

for immediate demolding Recommended post-curing conditions

Max Tg after post-cure

Toughness G1C after post-cure (2)

Conditions after 60 min cure time after 30 min cure time DSC mid point

Unit mPa.s °C °C °C J/m2

Araldite® LY 3585 / Aradur® 5003-1

440 - 500 at 40°C

60 80 2h at 120°C 120 - 130 180 - 230

Araldite® LY 1564 / Aradur® 5003-1

200 - 260 at 40°C

60 80 2h at 120°C 108 - 115 230 - 290

Resin XB 3518 / Aradur® 22962

300 - 400 at 30°C

80 100 2h at 140°C 125 - 135 150 - 180

Araldite® LY 3585 / Aradur® 3486

280 - 380 at 30°C

80 100 2h at 120°C 100 - 110 250 - 300


200 - 300 at 40°C

90 100 4h at 160°C 143 - 148 150 - 180

Araldite® LY 3585 / Hardener XB 3473

700 - 900 at 40°C

150* 160* 2h at 180°C 185 - 194 190 - 220

* Demolding < 120°C

(1) More products are available under request I (2) Measured with post-cure




Preforming epoxy binder for RTM Product Designation Softening point Tg Typical preforming cycle

Conditions DSC mid point

Unit °C °C

Araldite® LT 3366 ca. 150 75 - 85 20 ±10 sec at 180 ±20°C + cold stamping

Typical preforming conditions: cold pressing after infra-red heating



M3 roof parts with Araldite® XB 3523 / XB 3458

Benefits §  Parts with combination of low weight, high stiffness and high dimensional stability §  Fashion / aesthetics due to visibility of carbon fabrics structure §  Class A finish §  Low shrinkage

Araldite® solution for BMW Automotive composites > Mass production > Pioneer in RTM > Huntsman expertise > < Table of content


Aventador LP700-4’s chassis with Araldite® XB 3518 / Aradur® 22962

Benefits §  Low viscosity during injection §  Sufficient pot life §  Medium to high reactivity §  Low shrinkage (surface quality) §  High mechanical properties (good balance Tg / toughness) §  Good hot / wet properties

Araldite® solution for Lamborghini Automotive composites > Mass production > Pioneer in RTM > Huntsman expertise > < Table of content


Engine air box with Araldite® LY 3585 / Aradur® 3486

Benefits §  High complex, lightweight part produced in a single shot injection §  Inserts and internal auxiliary structures formed during RTM process

Araldite® solution for engine air box Automotive composites > Mass production > Pioneer in RTM > Huntsman expertise > < Table of content


Main features and benefits §  Design freedom §  Short cycle time §  Industrial process for medium volume car

part production §  High quality – reproducibility §  Integrated function (eg. number of parts

reduction, metallic insert integration…)

Standard pressure vs. high pressure RTM

RTM principle

View the process video




Low pressure: static mixer




High pressure: mixing chamber

* HP-RTM requires the use of internal release agent, which can either be pre-dosed in the resin or mixed as a third component directly in the mixing chamber. FPL functional scheme: with courtesy of Cannon




Compared processing conditions STANDARD RTM Low pressure

FAST RTM High pressure

Mixing configuration Static mixer Mixing chamber

Mixing pressure < 15 bar > 15 bar

Mold pressure < 15 bar > 15 bar

Typical total cycle time > 15 min < 15 min



Wet compression molding process

Wet compression molding principle

Main features and benefits §  Very short cycle time §  No injection step §  Low investment vs. high pressure RTM §  Suitable for “simple” part production




Preforming epoxy binders solutions for High Pressure RTM

Key features Araldite® LT 3366 is qualified for mass production of powdered fabrics and preforms thanks to

§  High softening point preventing ply to ply adhesion §  Fast preforming cycle

Product Designation Softening point Tg Typical preforming cycle

Conditions DSC mid point

Unit °C °C

Araldite® LT 3366 ca. 150 75 - 85 20 ±10 sec at 180 ±20°C + cold stamping

Typical preforming conditions: cold pressing after infra-red heating




Production cycles comparison Fastest HP-RTM solutions Fastest wet compression molding solutions


Araldite® LY 3585 / Hardener XB 3458 (reference)


Araldite® LY 3585 / Hardener XB 3458 (reference)

Preform / fabric lay-up set (1)

0.5 min 0.5 min 0.5 min 0.5 min

Mold temperature 110 - 115°C 100°C 120 - 140°C 120 - 140°C

Injection up to 1 min (small to large part)

up to 0.5 min (small to medium part)

- -

Cure > 2 min > 5 min > 1 min > 2 min

Demolding

0.5 min 0.5 min 0.5 min 0.5 min

Part production time (minimum)

4 min 6.5 min 2 min 3 min


Reference: first generation solution qualified for the first CFRP mass production application (BMW “i” program) (1) Includes mold closure and vacuum

Advanced Materials


Araldite® LY 3585 / Aradur® 3475 Typical thermal and mechanical performance

Key features §  High latency during mold filling §  Very fast cure and demolding stiffness development §  High tensile elongation at break

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Araldite® LY 3585 / Aradur® 3475 (1)

Araldite® LY 3585 / Hardener XB 3458 (1)

(reference)

Tensile modulus

ISO 527-2 Neat resin

2 700 - 2 900 MPa 3 000 - 3 100 MPa

Tensile strength 75 - 80 MPa 75 - 80 MPa

Tensile elongation 8 - 10 % 4 - 6 %

DMA Tg onset (2) ISO 6721

CFRP 105 - 115°C 93 - 103°C

ILSS (3) ASTM D2344 58 MPa 60 MPa

Reference: first generation solution qualified for the first CFRP mass production application (BMW “i” program) (1) Data generated with 2phr internal release agent I (2) Torsion mode, 2°C/min, only Tg assessment on composites relevant since neat resins exotherm in molds (3) 50K UD, TVf 50%



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View the brochure on SlideShare With this brochure get an overview of our comprehensive range of “Araldite® composite formulated systems”.

Download our mobile apps on your smartphone With these apps select immediately the right: §  Araldite® industrial adhesive for your specific need §  Araldite® composite formulated system for your process / application Access the product description or send us an email to request the technical data sheet.

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For more information

www.huntsman.com/advanced_materials [email protected]

Europe Huntsman Advanced Materials (Switzerland) GmbH Klybeckstrasse 200 P.O. Box - 4002 Basel Switzerland Tel. +41 61 299 20 41 Fax +41 61 299 20 40

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Raising performance in automotive composites - Highlight

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