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1
Thermoset composite SMC for
on-line painting of Automotive
Body Panels
Transportation Weight Loss Diet Conference 2013 , Stuttgart
Speakers :
Marie-Laure GUEGAN, R&D Manager, IDI Composites Europe
Guillaume CLEDAT, SMC Key market developer, CCP Composites
2
Outline of the presentation
Painting Process
SMC Supply Chain
SMC Thermoset Composite
E-coating SMC Grade development
Commercialization
Transportation Weight Loss Diet Conference 2013 , Stuttgart
3
Painting Process
Molder / Automotive TIER 1 OEM
Off-line Painting of SMC Parts:
Molding Class A SMC
Primer Step Painting Assembly
Molder / TIER 1 OEM
SMC e-coating Process :
Molding SMC e-coating
Assembly
Cataphoresis
Painting
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Supply Chain
Raw materials and
equipments
manufacturers
Compounders Molders / TIER 1
suppliers OEMs
Glass fibers
Peroxides &
additives
Resins and
additives
Conversion Automotive
Truck, Bus
Agriculture
equipments
SMC formulation
Transportation Weight Loss Diet Conference 2013 , Stuttgart
5 Transportation Weight Loss Diet Conference 2013 , Stuttgart
•Created in 2011, mergure composite materials activities of Cray Valley,
CCP and Progress Plastics
•A company of Total group
•Unsaturated polyester and vinylester resin, low profile additive, gel coat
and bonding paste manufacturer
•950 employees 550 M $ turnover (2011)
•19 production sites on 4 continents
•10 % of staff dedicated to R&D and technical assistance
CCP Composites
Sao Paulo, Brazil
UPR, Gel Coats
Jeonju, South Korea
UPR, GelCoats, SMC, BMC, VE
Pasir Gudang, Malaysia
UPR, Gel Coats
Melbourne, Australia
Blend UPR ,Gel Coats
Stallingborough UK
UPR, Gel Coats
: CCP Plant
: Center of competence
Mississauga & Drummondville, Canada
Blend UPR , Gel Coats
Miranda Spain
UPR, Gel Coats
Drocourt, France
UPR, GelCoats, VE
Joinville & Caxias, Brazil
Gel Coats
USA 7 plants
UPR, Gel Coats
Boretto, Italy
Gel Coats
: Tolling/Operating Plant
Sao Paulo, Brazil
UPR, Gel Coats
Jeonju, South Korea
UPR, GelCoats, SMC, BMC, VE
Pasir Gudang, Malaysia
UPR, Gel Coats
Melbourne, Australia
Blend UPR ,Gel Coats
Stallingborough UK
UPR, Gel Coats
: CCP Plant
: Center of competence
Mississauga & Drummondville, Canada
Blend UPR , Gel Coats
Miranda Spain
UPR, Gel Coats
Drocourt, France
UPR, GelCoats, VE
Joinville & Caxias, Brazil
Gel Coats
USA 7 plants
UPR, Gel Coats
Boretto, Italy
Gel Coats
: Tolling/Operating Plant
Sao Paulo, Brazil
UPR, Gel Coats
Jeonju, South Korea
UPR, GelCoats, SMC, BMC, VE
Pasir Gudang, Malaysia
UPR, Gel Coats
Melbourne, Australia
Blend UPR ,Gel Coats
Stallingborough UK
UPR, Gel Coats
: CCP Plant
Miranda Spain
UPR, Gel Coats
Drocourt, France
UPR, GelCoats, VE
Joinville & Caxias, Brazil
Gel Coats
Boretto, Italy
Gel Coats
: Tolling/Operating Plant
Sao Paulo, Brazil
UPR, Gel Coats
Jeonju, South Korea
UPR, GelCoats, SMC, BMC, VE
Pasir Gudang, Malaysia
UPR, Gel Coats
Melbourne, Australia
Blend UPR ,Gel Coats
Stallingborough UK
UPR, Gel Coats
: CCP Plant
Miranda Spain
UPR, Gel Coats
Drocourt, France
UPR, GelCoats, VE
Joinville & Caxias, Brazil
Gel Coats
Boretto, Italy
Gel Coats
: Tolling/Operating Plant
6 Transportation Weight Loss Diet Conference 2013 , Stuttgart
FRANCE Vineuil (41) (SMC/BMC/CIC/MMC)
IDI Composites Europe
Privately held family company with 6 independent facilities,
Global formulator of thermoset composites (SMC, BMC)
oriented to customers needs,
High Performance oriented product lines with product and
customer diversification,
Experienced management teams,
Unmatched capabilities with over 40 years experience
IDI Industrial Dielectrics, Inc.
IDI Composites International
7
General characteristics of SMC and BMC
Two main kinds of thermoset composite compounds :
SMC « Sheet moulding compound »
Compression molding, larger parts, longer glass fiber (25mm
and longer)
BMC « Bulk moulding compound »
Injection molding, smaller parts, complex parts, shorter glass
fiber, lower glass content (about 15 / 20%)
Typical composition and main properties:
Density : 1.3 to 2
Service temperature : - 30 to +200°C
Flexural strength : 120 to 625 MPa
Tensile strength : 65 to 440 MPa
Design
Recyclable
Glass fiber
Mineral
fillers
UP resin
LP additives
Transportation Weight Loss Diet Conference 2013 , Stuttgart
8 SIA / SFIP – Douai – 13/06/12 8 SFIP – Douai – 13/06/12 8
Production / Molding - SMC
Assemble
Painting
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Main barriers to on-line painting were identified, five development
directions were followed up to achieve the required performances
Paint curing @ 200°C Resin chemistry
Higher thermal
stability
Painting process
« paint popping » issue Residual styrene
Minimization
Sealed surface
material
Curing
catalysis
Shrinkage control
Molding process
monitoring Material control
Conductivity SMC formulation
optimization Compatibility
with e-coating
Main barriers to on-line painting
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Low profile or low shrink additives
Material microstructure
Optimization:
VOC emissions
Residual monomer migration
Release agent migration
Much improved paint surface quality
versus SMC cosmetic surface
properties MEB picture of cured UP resin with
PVAc (1) or PS (2) based additives
(1)
(2)
Shrinkage control mechanism
1
2
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Thermal stability - TGA
Weight loss monitoring based on Thermal Gravimetry Analyzer
allows to simulate material behavior through the painting
process
Rise plateau total
Without 0,9 0,4 1,3
With 0,5 0,3 0,8
Without 0,6 0,4 0,9
With 0,4 0,2 0,6
Class A standard SMC
formulation
TGA (Weigth loss %)Initial cataphoris
simulation
- 35min @185°C
e-coating SMC Formulation
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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VOC Emissions – VDA 278
Reduction of organic compound emissions
Molding conditions : 120 sec @ 160/165°C / 2min
632
51
15
0
Standard class A
SMC formulation e-coating SMC
formulation
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Solvent uptake
SMC solvent uptake after a
two hour contact
in a Maduri / Amocco test device
Solvent :
Butyl acetate / Xylene blend (60/40)
Maduri test
0,52%
0,11%
0,17%
0,34%
0,00%
0,10%
0,20%
0,30%
0,40%
0,50%
0,60%
% p
rise e
n m
asse
+cataphoresis simulation -35 min @ 185°C
Standard class A
SMC formulation e-coating SMC
formulation
Stainless
steel plate
Glass cell
Solvant
O-ring Coupon
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Painting process - Heuliez
Stage 1 : Cataphoresis line
10 min @ 160°C
Transportation Weight Loss Diet Conference 2013 , Stuttgart
Stage 2 : e-coating
Degreassing
Wiping
Primer : 30 to 35 µm thick
Curing : 20’ @ 150/160°C
Surface correction
Blowing
Wiping
Color base : 15 to 20 µm thick
Clear coat : 25 to 30 µm thick
Curing : 20’ @ 150/160°C
15
Painting process - Heuliez
Primer
Base
+ clear coat
TEM analysis – Thickness
measurements
SMC
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Failure mode analysis 1/3
Failure analysis of painted parts based on SEM and EDX
cartography
Painting failure
– agglomeration
Failure due to TIO2 agglomeration in the primer layer
SEM/EDX Analysis
IUT Blois – TOURS University
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Failure mode analysis 2/3
Failure analysis of painted parts based on SEM and EDX
cartography
SMC failure – Cracks
SEM/EDX Analysis
IUT Blois - TOURS University
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Failure mode analysis 3/3
Failure analysis of painted parts based on SEM and EDX
cartography
Handling issue
Cl- : NaCl - Sweat
Analyse MEB/EDX: LP additive
supplier Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Surface smoothness
Improvement of edges
(poping suppression)
and
Long wave surface distortion
thanks to molding conditions
optimization
Surface smoothness measured
with BYK Wave Scan system
Byk Wave Scan LW SW DOI
Target LW < 8 10 <SW< 30 > 82
Std SMC + IMC 4,4 17,5 81,2
e-coating SMC 5,3 27,8 82,0
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Commercialization
SMC e-coating :
March 2011 Serial Production,
Volume 155T 75.000 parts annually
Applications
Peugeot 807 Citroen C8
Transportation Weight Loss Diet Conference 2013 , Stuttgart
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Conclusion
Development of SMC e-coating
No cross contamination of the cataphoreses process between
metal and SMC parts
Conductive Material allows for electrostatic Painting Process
Compatible with metal high temperature painting process
Design flexibility of molded parts
Reduced part weight, for lighter vehicle weight over metal
Commercialization and on-line Painting
Reduced scrap rates and improved cycle time due to simplified
paint process
Colors Management
Reduced part costs to OEM's through improved processing,
improved cure, and reduced scrap
Transportation Weight Loss Diet Conference 2013 , Stuttgart
22 Transportation Weight Loss Diet Conference 2013 , Stuttgart
Contacts
IDI Composites Europe www.idicomposites.com
Marie-Laure GUEGAN
R&D manager
marie-laure.guegan@idicomposites.fr
+ 33 (0) 685 037 918
Josy MANTET-GAY
Sales director
josy.mantet-gay@idicomposites.fr
+ 33 (0) 630 552 457
CCP Composites www.ccpcomposites.com
Guillaume CLEDAT
SMC Key market developer
guillaume.cledat@ccpcomposites.com
+ 33 (0) 680 11 29 28
Laurence MARECHAL
Marketing Director
laurence.marechal@ccpcomposites.com
+ 33 (0) 618 87 28 47
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