Liquid Compression Molding (LCM) Technology for Mass Production of Continuous Fiber Composite Epoxy Matrix Components Stephen Greydanus, Cedric Ball, Ian Swentek– Hexion Thomas Jaeger – Alpex Technologies Erich Fries – Krauss Maffei

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The car industry implements light weight solutions to comply with CO2 emission and fuel consumption reduction legislation

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How can we achieve a potential weight reduction of 70% at competitive part cost

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Source: Roland Berger

400 kg

320 kg

240 kg 200

kg 160 kg 120

kg

Current steel Optimised steel Aluminium Magnesium CFRP today CFRP ?

100%

-10 -20%

-40% -50%

-60% -70%?

Relative cost

50% material • 40 - 45% carbon fiber • 5 - 10% resin

50% processing • Quicker curing matrix • Process optimization • Near-end-contoured preforms • Automation

CFRP Epoxy Composites

Optimum CFRP performance and cost is complemented with good design

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Process Capability For OEM Industrialization

Materials Partnerships

Through Value Chain

Optimum Performance

and Cost

Liquid Resins Hot Melts Perform Binders Mould Release Agents

Prototyping Systems

Injection Moulding LCM Prepreg HP-RTM

Preforming SMC FiWi Towpreg

Equipment Suppliers Part Design and Modeling Process Design and Modeling Tool Fabrication

Reinforcements

Complimentary Manufacturing Processes: Resin Transfer Moulding (RTM) and Liquid Compression Moulding (LCM)

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Robust process technologies for rapid manufacturing of continuous fiber composites

Compatible for range of simple to complex part geometries

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HP-RTM Process Overview In the HP-RTM process, resin is injected into the fabric preform in closed matched metal tooling in a compression press

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Cycle time is driven by number of factors:

Press and injection equipment Part size and complexity Resin type and quantity Injection flow rate (driven by geometry and preform

permeability)

Preform tool Binder

Stabilized Fabrics

Press Injection Curing Opening & de-moulding

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LCM Process Overview

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In the LCM process, the resin is applied to the top of the fabric, either outside or inside the open tool cavity. The press then closes and resin is pressed into the laminate, primarily in ‘z’ direction

Liquid resin application

Transfer wet lay-up into

mould

Curing

Opening & de-moulding

Fiber preparation

Process and Cycle Time Advantages: Preforming not required for majority of compatible parts –

removing process step Faster impregnation of fiber than with RTM injection

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LCM cycle times of 50 seconds have been demonstrated

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Press closing

Impregnation

Curing

Press opening

LCM Moulding Tool - Cross Section

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Resin Pre-applied to Fiber Stack

Arrows showing direction of impregnation during mold closure

Upper Mould Tool

Lower Mould Tool

Fabric Stack

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Both RTM and LCM require technical expertise and process development

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RTM LCM

Resin Flow/Fiber Impregnation (during Injection)

Resin Flow/Fiber Impregnation (during Mold Closure)

Liquid Compression Molding (LCM) is cost attractive with increasing complexity of parts

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Low Part complexity

Cos

t Pr

efor

m re

quire

men

ts

Proc

ess

com

plex

ity

High

High

RTM

LCM

Considerations to compare for CFRP part cost

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Process RTM High Pressure - RTM LCM

Injection rate (g/s) 40 100 100

Process temperature (°C) 120 120 140

Cavity pressure (bar) 15 80 30

Required injection time (s) 60 24 N.A.

Tool cycle time (s) 360 93 50

Injection equipment 3K RTM 3K HP-RTM 3K RTM

Press (ton) 500 2.500 1.000

Tooling cost Relative x1.5 x2 1

Build rate pc/year 20.000 70.000 120.000

Fixed tooling cost/part Relative x11 x4 1

Dimensions : 1500 mm x 1200 mm x 3mm Volume (cm3) : 5.400 Resin amount (g) : 2.400

Example Part -

The part size and equipment determine the material processing window

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Part

0

1000

2000

3000

4000

5000

6000

7000

0 20 40 60 80 100 120

Resin Injection rate (g / sec) 60 g/s

Injection time (sec)

Resin Shot weight (g)

EP TRAC 06170 EK TRAC 06170

33 sec

EP TRAC 06150 EK TRAC 06165

45 sec

EP TRAC 06150 EK TRAC 06150

95 sec

80 g/s 100 g/s

80% of Moulded parts

Equipment

Material

The BMW 7-Series Carbon Core illustrates body-in-white mixed material use

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BMW 7-Series Various CFRP parts e.g. roof arc and tunnel reinforcement BMW SOP: 2015

Source: BMW Group

Benefits • 40 kg weight reduction vs. steel in the Carbon Core body structure • Fast curing cycle enabled by Hexion latest resin technology • Multi material mix – engineered to performance

Applications - Epoxy CFRP LCM & RTM technology for structural applications

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BMW 7-Series CFRP roof arc EP TRAC 06000/ EK TRAC 06130

Benefits • Local reinforcement enhances

torsional stiffness

BMW 7-Series CFRP tunnel reinforcement EP TRAC 06000/ EK TRAC 06130

Benefits • Designed to the shape of the car body • Fast curing cycle with HP-RTM • Outstanding weight / performance ratio

Complex part geometry requires HP-RTM process

Simple geometry of part is compatible with LCM process

Key Takeaways

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Liquid Compression Molding (LCM): Complimentary moulding process to HP-RTM for molding simple to complex geometry composite parts

Key LCM process benefits: Fastest process technology for manufacturing continuous fiber composites today – Cycle times less than 90 seconds

Cost competitive: Robust processing and rapid cycle time for LCM manufacturing makes Epoxy CFRP increasingly competitive as a lightweighting technology

Thank you!

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Stephen Greydanus Automotive AD and TS Manager NA Stephen.Greydanus@hexion.com

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