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
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
(%)
• 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)
• 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
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
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
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
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
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
• 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
11
BMC Composite Material Composition(Wide Range of Materials/Properties)
Composite Cost Comparison
On a cost / unit volume basis thermosets offer significantly higher value compared to many High Performance Thermoplastics.
13
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
14
BMC vs. High Performance Materials
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
• 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
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.
18
• 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
19
• 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
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
Rigidity at Elevated Temperature(BMC vs. Engineering Thermoplastics)
22
• 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)
120°C 2000hr Long Life Coolant Exposure
150°C 2000hr ATF Exposure
BMC Property Retention vs. Fluid Aging150°C 2000hr Engine Oil Exposure
24
• 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
25
• 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
26
• 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)
27
• 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)
28
• 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)
29
• 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