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17-8.09.2010
ACRC
CARBON FIBRE INNOVATION FOR HIGH VOLUMES:
THE FORGED COMPOSITE
CARBON FIBER IN AUTOMOTIVE MARKET
Automotive applications of carbon fibre reinforced plastics (CFRP) are increasing.
Lucintel, the premier global management consulting firm, revised upward its forecastof growth in the carbon fibre market from 9.8% per year over the next five years to13% per year.
BMW, Mercedes-Benz, Lamborghini and other high-end automakers havecommitted to the increased use of CFRP components in their vehicles to reduceweight.
Daimler has set a body in white weight reduction target of up to 10% for all of its
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Daimler has set a body in white weight reduction target of up to 10% for all of itsmodels and is looking to carbon fibre materials for some of that weight saving.
The SGL Group reported that sales in its Carbon Fibres & Composites businessincreased by 6% in the first nine months of 2010.The SGL Automotive Carbon Fibers GmbH joint venture with BMW is dedicated toproducing carbon fibre for BMW’s Megacity vehicle, the company’s first productionelectric car.The car is being called the world’s first large-scale production vehicle designed with aCFRP passenger cell.
CARBON FIBER IN AUTOMOTIVE MARKET
Mercedes-Benz has been using carbon fibre composites since 2004, when the seriesproduction of the SLR McLaren high-performance sports car was launched. Today, thelatest model, the McLaren MP4-12C supercar, features a CFRP MonoCell tub, mouldedas a single-piece that is designed to protect the occupants.
Chevrolet has introduced the 2011 Z06 Carbon Limited Edition Corvette, whichfeatures a carbon fibre hood, roof panel with a full-width body spoiler, rocker panelsand air splitters. But the 2011 Corvette ZR1 carries even more carbon content – eightcomponents with a total weight of 34 lbs (15.4 kg) or one half the weight of
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components with a total weight of 34 lbs (15.4 kg) or one half the weight ofequivalent glass fibre SMC [sheet moulding compound] parts.
Lamborghini has also stated that it intends to add more CFRP components to itsvehicles. A high priority is the development of out-of-autoclave curing to increase theproduction rate and reduce costs for future vehicle systems.Lamborghini recently introduced its CFRP demonstrator concept, the Sesto Elemento,which weighs only 999 kg (2204 lbs).
FORGED COMPOSITE – TECHNOLOGY OVERVIEW
FORGED COMPOSITE is produced by SSSSheet MMMMoulding CCCCompound process with carbonfibres (opposited traditional glass fibre SMC) It uses pre-fabricated sheet material madeof vinylester resin and short length carbon fibres (chopped fibers).
FORGED COMPOSITE should not be confused with traditional GF-SMC. The primaryadvantages of carbon fibers in FORGED COMPOSITE are higher modulus and lowerspecific gravity relative to glass fibers. The modulus of commercial-grade carbon fibersis more than four times higher than E-glass fibers!
FORGEDFORGEDFORGEDFORGED COMPOSITECOMPOSITECOMPOSITECOMPOSITE GFGFGFGF –––– SMCSMCSMCSMC ((((25252525%%%% GF)GF)GF)GF)TensileTensileTensileTensile strengthstrengthstrengthstrength 230 MPa 80 MPaYoung’sYoung’sYoung’sYoung’s ModulusModulusModulusModulus 55,000 Mpa 12,500 MPa
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Young’sYoung’sYoung’sYoung’s ModulusModulusModulusModulus 55,000 Mpa 12,500 MPaDensityDensityDensityDensity 1,48 Kg/dm3 2 Kg/dm3
FORGED COMPOSITE raw material
P=60 barT = 127 C
Curing time 5min
+ stiff+ design flexibility+ integration options
Manufacturing process Example: Sesto Elemento A-arms
Material Performance
Preforming into 1 carrier
Automatic preforming is possible
Material squeezed in the tooling by applying pressure about 60 bars
FORGED COMPOSITE – TECHNOLOGY OVERVIEW
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FC process
1. Cuttingof preforms
2. Preformingontocarrier
3. Apply chargein mouldby carrier
4. removecarrier
5. Mould 6. Eject /Part finished
• Resin comparison in plate characterisation
MASS PRODUCTION – THE FORGED COMPOSITE
30
345
37
75
5,25
60
80
100
120
140
Te
mp
era
ture
in
°C
Curing and Post RTM vs FORGED COMPOSITE press moulding
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75
0
20
40
0 50 100 150 200 250 300 350 400
Te
mp
era
ture
in
Time in min
Curing RTM/Press Moulding Hexion Post Curing Oven Hexion Curing RTM/Press Moulding Huntsman
Post curing Oven Huntsman Curing FORGED COMPOSITE/Press moulding
RTM vs FORGED COMPOSITE
RTM*
163 min
Prep Moulding Post-processing
Forged composite has very short curing time
Process time is reduced by 44% plus advantage of reduced part count
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0 100 200 300 400 500 600
Process time [min]
Process time
Forged
Composite
26 m
in
*: Process of 1 part (largest) part
- 44%
FORGED COMPOSITE – SAMPLE COSTS OVERVIEW
RTM TUB
100%
FORGED COMPOSITE TUB
110%Weight
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100 %
100 %
100 %
80 %
50 %
71 %
Normalizedmaterial cost
NormalizedManufacturing time
NormalizedPart price
THE “SESTO ELEMENTO”
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Technology demonstrator: 20 cars planned to be sold in 2011
Almost entirely carbon fiber composite structure
Dramatic weight reduction 999Kg vs. 1560 lb baseline
Innovative content
Carbon fiber wheel/ hubs
Wrapping Carbon fiber driveshaft
Integral carbon bodyshell in Forged Composite
New high temp carbon exhausts Pyrosic
THE “SESTO ELEMENTO”
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New high temp carbon exhausts Pyrosic
Forged composite technology in suspension arms
One-piece carbon monocoque
Integrated seats
Carbon crash box
Titanium fasteners vs. aluminum inserts
THE “SESTO ELEMENTO”
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Redesigned CFRP lower front Original forged aluminum lower
8 parts total (4 different designs), 2 fronts and 2
rears, 2 uppers and 2 lowers
Result: -30%, rate improved (total cycle time 3
mins), cost reduced ($32 per part)
THE “SESTO ELEMENTO” SUSPENSION ARMS
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Redesigned CFRP lower front suspension arm assembled and
finished
Original forged aluminum lower front suspension arm assembled and finished
Forged composite mechanical properties are not yet comparable with Pre-preg and
RTM standards
Lamborghini has completed material characterization and validation o f Hybrid
structures as follows:
FC + Unidirectional
FC + Fabric
FORGED COMPOSITE – HYBRID STRUCTURES
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FC + Fabric
Lamborghini is developing hybrid Forged composite panels to fulfil A-class surface
requirements
Combination of Forged composite with Unidirectional fibers gives the opportunity to
obtain parts fulfilling the automotive A-class surface requirements
� Composite mass production is already the present
� High performance composites materials combined with high volumes
production rate are achievable
� A class surfaces body panels under development
� Sesto Elemento shows the potential of the Forged composite in terms of:
FORGED COMPOSITE – CONCLUSION
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� Sesto Elemento shows the potential of the Forged composite in terms of:
� Production rate
� Costs
� Feasibility
� Structural behaviour
� Joining technology (Hi-Lok)
� Co- Bonding
� Forged Composite is the future of structural and non structural composite
application
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