mandatory checkpoints for a higher composite market...

Mandatory Checkpoints

for a Higher Composite

Market Share in

Automotive

[email protected] -

15 / 03 / 2017

mailto:[email protected]?subject=Contact suite à présentation JEC CETIM du 09/02/2017

Agenda

JEC World – 2017 – 03 - 15 2

Faurecia Composite Technologies 1

Where do composites stand ? 2

Acting on the Composite value chain 3

Conclusion 4

3




Conclusion 4

JEC World – 2017 – 03 - 15

4

Faurecia Clean Mobility Composite Technologies, a division of Faurecia’s strategy in Clean Mobility

Innovations

Passenger cars emission control

CV

on-Highway

Exhaust Energy Recovery Innovations

Lightweight Innovations

Exhaust Energy Recovery Innovations

Lightweight Innovations

CV

off-Highway

High Horse Ppwer

Lightweight composite solutions Energy Recovery

for Electrical Vehicle

Real Time Data Fuel Cell Technology

CV Off-highway and

HHP

Adjacent clean solutions

for EV

Air Quality Innovations: Heated Catalyst, ASDS, Turbo Gas, EGR

Current business – Traditional

portfolio

Building blocks towards Cleaner Solutions

#1 worldwide in mechanisms & seats structure

#3 worldwide in complete seats

#1 worldwide interior vehicle

#1 worldwide in emissions control technologies

A global leader in its 3 activities

JEC World – 2017 – 03 - 15

Drive the transformation of the global Mobility Value Chain

towards Cleaner Solutions

Faurecia Composite Technologies A transversal center of expertise for Faurecia Group activities

5

Interiors Seating Clean Mobility

o Heat Shields

o Temp. resistance

o Acoustic / NVH

o Functional integration

o H2 tanks

o Seat Structures

o Luggage crash

o Aspect (B-side)

o Acoustic / NVH

o Functional

integration

o A-class body

o Closures

o Rear/side crash

test

o Functional

integration

o Semi-structural & Structural

o Crash resistance &

absorption

o Stiffness & Rigidity

o Underbody / Aero & Skid

Shields

o Acoustic / NVH

o Impact resistance

o Cross-car Beam

o Crash

EV

o Battery Protection

o Crash absorption

o Heat resistance

o Fnct. integration

o A-class

o Semi- & Structural

o Painting

o Functional

integration

Body

Customers

JEC World – 2017 – 03 - 15

6




Conclusion 4

JEC World – 2017 – 03 - 15

Market trend for mass market

7 JEC World – 2017 – 03 - 15

Time

CO2 emissions

Cost penalty acceptance* +

-

General understanding Performance

Time

No market

No market

2€/kg saved

3€/kg saved

New achievable

market

Potential for more application driven by better cost penalty acceptance

* Exact figures depending on :

• OEM

• Product

• Place in the vehicle

• Production volume (incl. tooling influence)

BMW case study

8

2013 2014 2016

BIW combining steel / aluminum / CFRP 16 CFRP parts

BMW i3 BMW i8 BMW 7-series

Oct 2016: BMW announces they will limit the use of CF, turning instead to lightweight steel to keep profit.

CF Life Module (BIW / Life Module) Aluminium Drive Module

Life Module

Drive Module

Towards an architecture including composites ‘just-where-needed’

instead of a complete BIW in composite

JEC World – 2017 – 03 - 15

Composite Competition

Metal : Magna Example

Ultralight door architecture with 42.5% weight savings

Extensive use of aluminum

“Contributions in the area of molding techniques and polymers

represented approximately 7% of the total mass reduction”

“The target in terms of cost was approximately $5 per pound and

we came in at $2.59 per pound”

9

Ultralight Door Module - Magna

Composite application in mass market is not established

JEC World – 2017 – 03 - 15

10




Conclusion 4

JEC World – 2017 – 03 – 15

Status on composites The composite value chain

11

Expectation

Lever - Reduce raw material price

- Reduce semi-finished products

- Material compliance with quick processes

- Tailored mechanical performance

- Speed - Reduce waste

- Reduce scrap - Reduce post

molding activities - Automation

- Tailored design - Function

integration

- Hybrid assembly

- Speed - Reliability

- Reduce trial number - Increase material

knowledge & accuracy

- Eng. & Devlt. time reduction

- Global costing approach

Raw material

Process Product Assembly Engineering

€ € € € €

Mandatory to act on multiple levers of the composite value chain

JEC World – 2017 – 03 – 15

Mid term Target for composite : -20 to -40% on total cost vs today

Levers

12




Conclusion 4

JEC World – 2017 – 03 - 15

Raw material


Material Carbon price reduction

Currently carbon cost ~ 13€/kg

Not enough cost decrease

Next steps :

Working on the carbon fiber value chain to reduce

useless steps

2020: OakRidge US National lab: 11€/kg

2023: FORCE : 8€/kg

13

Carbon fiber cost divided by 2 over a duration of 8 years

JEC World – 2017 – 03 – 15c

Raw material

Material Working on material to reduce cycle time

Fast cure : Application in 2012 on serial life production case

14

Potential to reduce even more but bottleneck : Surrounding operations Looking for next step

Closed press 21’10’’ Open press

2’00’’

Preform

introduction

2’00’’

Mold

closing

0’35’’ Closed mold 20’00’’

Mold

opening

0’35’’

Deburring

1’30’’

Weighing

0’30’’

Next

preform

preparation

3’30’’

Operator is waiting 15’00’’

Open press 6’00’’

Demolding

3’30’’ Shaper

0’30’’

Mold cleaning

2’00’’

Initial cycle time 29’10’’

Closed press 6’40’’ Open press

2’00’’

Preform

introduction

2’00’’

Deburring

1’30’’

Weighing

0’30’’

Next

preform

preparation

3’30’’

Fast cure cycle time 14’40

Mold

closing

0’35’’

Mold

opening

0’35’’

Demolding

3’30’’ Shaper

0’30’’

Mold cleaning

2’00’’

Closed mold

5’30’’

Open press 6’00’’

Operator is waiting 0’40’’

Time cycle / 2

JEC World – 2017 – 03 – 15c

Raw material

15




Conclusion 4

JEC World – 2017 – 03 - 15

Raw material


Process Reconsider both Material and Process

New processes require to reduce semi-finished products.

Benefits :

Cost

Geometry freedom

Benefit from specific material property + flexibility

Reactive Thermoplastic RTM Example

In mold combination of dry fabrics and resin

Integration of ribs

Very high fluidity of caprolactam grants a better fiber impregnation

Opportunity to increase fiber content ratio

Reduce cycle time and clamping force

Net-shape part production

16 JEC World – 2017 – 03 – 15c

Process

Process Reconsider both Material and Process

Key points:

Integration of Fast form benefits

Program ends : Dec’ 2017

Part to part target : 120sec

Currently 157sec

17

Fully automated process compliant with automotive mass market

JEC World – 2017 – 03 - 15

Process

18




Conclusion 4

JEC World – 2017 – 03 - 15

Raw material


Product Reduce cost and weight

19

Benefit of highly adaptability of composites

Global spec.

Architecture.

Detailed spec.

Detailed design

Unitary test

Integration test

Validation test

Time

Det

ails

Function integration

Move from black metal approach

Function integration

Shape freedom, tooling, assembly…

Speak at higher level in the development V-cycle

Benefit of tailored design opportunities

Put the right material at the right place

Playing on

Stacking sequence

Glass / carbon or Hybrid metal mix

Reinforcement volume ratio

Overmolding

JEC World – 2017 – 03 - 15

Product

20




Conclusion 4

JEC World – 2017 – 03 - 15

Raw material


Assembly

Hybrid assembly

Magnetic Pulse Spot welding

Benefits

Metal insert ok for manufacturing (easier than )

Compatible with multi-material welding with BIW : steel, steel+zinc, aluminum…

21

Assembly process compliant with existing OEM assembly line

Coil

Flyer Sheet

with Hump Composite Plate with

Metallic Insert inside

Air gap Welding

Metallic Insert Steel

Steel + Zinc: e≈0,49µm

Zinc: e≈3,8 µm

Alu + Zinc: e≈3,5 µm

Alu

Welding analysis : perfect adhesion

JEC World – 2017 – 03 - 15

Assembly

22




Conclusion 4

JEC World – 2017 – 03 - 15

Raw material


Engineering Enhanced Engineering scheme

23

If n

ot

OK

Important evaluation times

No process – product coupling

- Negligible computation time increase by process and costing consideration

- Mechanical simulation and costing predictions enhanced with Process Estimator outcome

JEC World – 2017 – 03 - 15

Engineering

Engineering Example of part optimization

7 zones with independent material lay-up

UD and chopped fiber material (carbon & glass)

Zones defined using topology optimizations with an isotropic

material

Main process parameter is the injection time (fixed curing time)

Optimization results:

24

Important part cost reduction with process consideration

Standard approach Enhanced approach

Part mass: + 5 %

Part filling time: - 96 %

Total cycle time: - 29 %

Total part cost: - 10 %

100&

100 %

100&

100 %

JEC World – 2017 – 03 - 15

Engineering

Engineering

25

SB63G1-T1.5 HSR 45-degree angle

0

50

100

150

200

250

0 5 10 15 20 25

Strain (%)

Str

ess

(M

pa

)

HSR Tensile 45° 23C - 0.1 s-1

HSR Tensile 45° 23C - 2 s-1




Optimization

Crash / Energy absorption :

Manufacturing

PROCESS

Raw Materials And

Sub-Process

PRODUCT Design

Assemblies

Pre-forming / wrapping

Thermoforming

Composite / Composite or

Composite / Metal

Material Laws

SIMULATION applied to COMPOSITES

Optimization Optimization

JEC World – 2017 – 03 - 15

Engineering

Engineering Product & Process link

26

Thermoforming simulation

Process simulation results, Input for product simulation

Trial

Trial

Product simulation without process consideration

Product simulation with process consideration

Mandatory to consider product-process dependency for complex parts

JEC World – 2017 – 03 - 15

Engineering

27




Conclusion 4

JEC World – 2017 – 03 – 15c

Conclusion

28

Not one single value for target price per kg saved

Composite deployment in Automotive mass market is not established.

Carbon has the highest potential for improvement

Mandatory check points :

Important cost reduction and development of efficient engineering tools

To act on multiple levers in the composite value chain

To work jointly with OEM’s : to speak at higher level than part spec

JEC World – 2017 – 03 – 15c

mandatory checkpoints for a higher composite market...

Documents