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©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
International AVK Conference
13./14. September 2010
Dr. Hartwig Lohse
Bonding of Composite Materialsin Automotive Engineering –
Opportunity for a Reduction of CO2-Emissions
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©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Introduction
Introduction
Adhesive Bonding – a next generation technology
Adhesives for bonding composite materials
Joint design for adhesive bonding
Processing and cross-linking of adhesive in series production
New applications, progress and trends - Outlook
Inhalt
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©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
Composites in Automotive Engineering
1946: Stout `46 Case study by Owens Corning – fullcomposite car body
1972: Renault 5 First SMC bumper
1980: Audi Ur-Quattro boded SMC trunklid
1984: Renault Espace Composite side panels bonded to thehot dipped steel body structure
1982: Citroen BX First high volume passenger car withSMC/BMC exterior body parts (SMC-front hood, BMC liftgate)
1989: Volvo Truck bonded SMC air deflector
2002: PSA/FIAT individualization through SMCliftgates
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Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Introduction
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
Design freedom
Individualization
Cost benefits at low to medium volumes – speed to market
Fully permeable to radio signals – antennas can be invisiblymounted within the component
Sound dampening properties
Corrosion resistance
Weight reduction
Composite Materials in Automotive Engineering
4/26
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Introduction
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
Government regulators demand ever high fuel economyperformance and lower CO2-emissions. – EU 443/2009 definesthe OEM-average CO2-emission of newly registered cars haveto be below 95 g/km.
Car manufacturer‘s response:
Optimization of the power train (engine, gear box).Cylinder capacity reduction by maintaining performance
Hybrid engine – Electro car
Reduction of air and rolling drag
Weight reduction (100 kg 8,5 g CO2/km = 0,3 l/100 km)
…
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5/26
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Introduction
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de6/26
An Assessment of Mass Reduction
Opportunities for a 2017 – 2020 Model YearVehicle Program
Prepared by: Lotus Engineering Inc.
Submitted to: The International Council on CleanTransportation (ICCT)
March 2010
Weitere Informationen ICCT: www.theicct.org
Based on Toyota‘s Verza 2009 model weight reduction measures by usingalternative materials and joining technologies are discussed
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Introduction
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de7/26
Steel
100 %
> 400 individual parts/ 382 kg 211 individual parts/221 kg
Steel
5%
Aluminum
37%
Magesium
30%
Composites
21%
High strength steel
7%
An Assessment of Mass ReductionOpportunities for a 2017 – 2020 Model
Year Vehicle Program
Prepared by: Lotus Engineering Inc.
Submitted to: The International Council on CleanTransportation
March 2010
Body Structure
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Introduction
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
2002: Aston Martin Vanquish
CFRP-transmissiontunnel bonded to the
aluminum bodystructure
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Source: J. Hill, Automotive CircleInternational Bad Nauheim 2002
CFRP-Crash structurebonded to cast
aluminum strut towers
SMC-Side panel
~ 15 Liter Adhesive
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Introduction
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
2004: BMW M3 CSL – CFRP-Roof, bondedto the body structure
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Weight reduction andimproving center ofgravity
m = 5,6 kg
9,2
4,7
11
6,9
3,6
0
2
4
6
8
10
12
Stahl (0,8 m m) Alu (1,2 m m) SMC (4 mm ) GFK (3 mm) CFK (1,8 m m)
Material (Stärke)
Ma
ss
eD
ac
h[k
g]
BMW Group
BMW M3
BMW M3 CSL
BMW M3
BMWM3 CSL
Today : Standard for all BMW M-models
Source: R. Haider, H. Lohse -Adäsion 12/2004
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Introduction
Steel (0,8 mm) Al (1,2 mm) SMC ( 4 mm) FRP 3 mm) CFRP 1,8 mm)
Material (thickness)
Weig
ht
of
the
roof[k
g]
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
BondingBonding –– a nexta nextgenerationgenerationtechnologytechnology
Material:
Combination of differentmaterials
(e.g. thermoset/thermoplastic,plastic/metal, …)
Processing:
Maintaining materialproperties
(e.g. surface, no thermal defects,stress distribution to a large area,…)
Integration of additionalfunctions:
e.g. tightness, therm./electr.conductivity, sound dampening, …)
Construction/Design:
Improved part performance
(e.g. weight reduction, stiffness,design opportunities, …)
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10/26
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bonding – A next generation technology
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
Factors determining strength and durability of a bondaccording to: G. Habenicht, Kleben – Grundlagen, Technologien, Anwendungen, Springer Verlag, 4.Aufl.
Adhesive
Part geometry Stress
Quality of thebond
Bond
Bond design
Adhäsionsschicht
Substrate
Surface
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11/26
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bonding – A next generation technology
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
Due to it’s interdisciplinary character a successful introduction ofadhesive bonding into production requires a close cooperationbetween all involved parties and a competent project management.
This is the only way to assure that all parameters fit together.
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Material properties
Surface preparationPart-handlingCycle timeTolerancesVolumeApplication technologyCure conditionAdhesion
Form of the adhesivemechanical propertieschemical resistance of the AdhesiveEH&SQuality assurancecostsetc.
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bonding – A next generation technology
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
A competent, experiencedproject management is required
to avoid that at the end onepiece is missing in puzzle.
Material supplier
Customer
Equipment supplier
Adhesive user
Adhesive supplier
(external Consultant)
Part supplier
‚legislative body‘
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13/26
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bonding – A next generation technology
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering–Adhesives for bonding composites
Lap
Sgear
Str
ength
[MPa]
Elongation [%]
10
20
30
40
100 200 300 400
2-k Epoxy
2-k-Acrylate
structural2-k-Polyurethane
1- & 2-k highelongation adhesives
Adhesives in use for composite bonding
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©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
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Outer panel
Reinforcement
Metal insert(KTL)
Hinge (KTL)
16-25 mm
>3 mm
1 – 1,5mm
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Example: Fronthood
Source: S.Schäfer -European Alliance for SMC, Bremen 2004
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bond line design
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
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Avoiding Bond Line Read Through (BLRT)
Besides the mechanical properties of the materials to be bondedthe following has to be considered:
Use of adhesives with low shrinkage
Maintain constant joint thickness
Substrate 1
Substrate 2
Adhesive
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bond line design
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
17/26
Avoiding Bond Line Read Through (BLRT)
Besides the mechanical properties of the materials to be bondedthe following has to be considered:
Use of adhesives with low shrinkage
Maintain constant joint thickness
Avoid molded-in spacers
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bond line design
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
18/26
SMC
SMC
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bond line design
Avoiding Bond Line Read Through (BLRT)
Besides the mechanical properties of the materials to be bondedthe following has to be considered:
Use of adhesives with low shrinkage
Maintain constant joint thickness
Avoid molded-in spacers
Avoid adhesive squeeze out
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
19/26
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bond line design
Avoiding Bond Line Read Through (BLRT)
Besides the mechanical properties of the materials to be bondedthe following has to be considered:
Use of adhesives with low shrinkage
Maintain constant joint thickness
Avoid molded-in spacers
Avoid adhesive squeeze out
Avoid stress resulting from different thermal elongation
Assure constant cure conditions
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
Avoiding Bond Line Read Through (BLRT)
Besides the mechanical properties of the materials to be bondedthe following has to be considered:
Use of adhesives with low shrinkage
Maintain constant joint thickness
Avoid molded-in spacers
Avoid adhesive squeeze out
Avoid stress resulting from different thermal elongation
Assure constant cure conditions
Avoid a thermal damage of the surface as a effect of a too highcure temperature
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20/26
ThermischeSchädigung derOberfläche
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bond line design
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
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Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bonding process
21/30
Reinforcement Outer panel
cleaning cleaning
MixingPot Life
PartA
PartB
Dispensing
Joining
Open Time
Clamping
Heat acceleratedCure to reach
handling strength
Further Processing
Remove from FixtureAmbienttemperature cure to
reach handlingstrength
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
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Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
Bonding process
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
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23/26
Hybrid – Liftgate
ThermoplastischeAussenhaut
MagnesiumStrukturteil
A ICCT proposal is mentioning magnesium as material for the reinforcing part.Based on experience from VW‘s Lupo-based 3-Liter-vehicle, showing problemswith corrosion protection of magnesium (costly to achieve) a SMC reinforcementhas been considered for a new model being introduced to the market this year.
Novel adhesives with special properties, mainly in regard to BLRT, goodadhesion to thermoplastics as well as SMC and good low temperature cureproperties are required.
SMCreinforcement
A first car with a hybridlifgate will be launched at
the Paris Autoshow02. – 17. Oct. 2010
Thermoplasticouter panel
(PP/EPDM, ABS,ABS/PC, etc.)
Abb.: ICCT
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
New applications, progress and trends - Outlook
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
24/26
Use of Carbon-Fiber-Materials
Carbon-Fiber-SMC for closures, e.g. Porsche 911 GT3 II
CFRP Body and Body parts, e.g. Tesla Roadster
SMC outer panel, C-SMC reinforcement
1,3 kg weight reduction compared to SMC/SMC
High performance electric sports car(288 PS - 212 km/h – 3,7 sec 0 – 96 km/h)Epoxy- und Polyester- carbon fiber body panels in conjunction with analuminum monocoque chassis
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
New applications, progress and trends - Outlook
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
25/26
Use of Carbon-Fiber-Materials
BMW MEGACITY CAR –
First volume-produced vehicle with a passenger cell madefrom carbon fiber materials – SOP 2013
The light weight concept allows topractically offset the extra 250-350 kgof weight typically found in electricallypowered vehicles.
2 horizontally separated modules
• Drive Module: aluminum chassis as solidfoundation integrating the battery, drive systemand basic crash functions
• Life Module: high strength light weight CFRPpassenger cell
Dr. Hartwig Lohse
Bonding of Composite Materials in Automotive Engineering
New applications, progress and trends - Outlook
©© Klebtechnik Dr. Hartwig Lohse e.K.Klebtechnik Dr. Hartwig Lohse e.K.
www.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.dewww.Howwww.How--DoDo--YouYou--Glue.deGlue.de
26/26
Many Thanks For YourAttention
Questions?
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Dr. Hartwig Lohse
Klebtechnik Dr. Hartwig Lohse e.K.Fraunhoferstr. 325524 ItzehoeTel.: +49 4822 95180E-Mail: hlohse@hdyg.de
International AVK Conference
13./14. September 2010
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