MATERIALES COMPUESTOS EN AUTOMOCIÓN, ¿CUÁNDO y … · materiales compuestos en automociÓn,...

Meeting your challenges

Jatsu Intxaurbejintxaurbe@batz.es

MATERIALES COMPUESTOS EN AUTOMOCIÓN,

¿CUÁNDO y CÓMO?

BEC, 5th June of 2014

MATERIALES COMPUESTOSEN AUTOMOCIÓN,

¿CUÁNDO Y CÓMO?

• ¿ POR QUÉ ?• ¿ DÓNDE ?

• Why?

• Where?

• When ?

Triad: North America - EU Big 5 – Japan/Korea

Brazil – Russia – India - China

2008

68mn

BRIC

Resto Mundo

Triad 60%

28% 37%

46%

2013

89mn

43%

41%

2018

116mn

The automotive sector grows globallybut moves toward the BRICs countries

CO2 EMMISSIONS REDUCTION BY

AERODYNAMIC PERFORMANCE

Sleek design for greater efficiencyAerodynamic performance means less air resistance, that is lower CO2 emissions

Optimal surface for greater efficiencyAdvanced composites are the main actors in the underbody panels

Up to 5% Cx reduction due to underbody paneling

THE CHALLENGE IS THE

WEIGHT REDUCTION

Light & Safe, the current paradigmFuture cars BIW structures should increase the safety although being lightweight and environmentally friendly

DIFFERENT TECHNICAL SOLUTIONS LOOKING FOR THE SAME GOAL

Advanced steels, still leadersNowadays all OEMs are using new generation steels to increase safety and decrease weight

CASOS NO COMPOSITES

Luxury cars, exotic solutionsSome advanced solutions still are not trends for common cars

Average use of Mg is 2.5 Kg per vehicle 26 Kg in some sportive model

An overview approach should be mandatoryAutomotive is working for minimize the totaldioxide carbon footprint using Eco-Design parameters

Aircrafts, lightweight trends exhibitorAdvanced technologies based onwell known composites solutions

AUTOMOTIVEINDUSTRY

COST EFFICIENCY

Key question for the composite promotingRational use of the technology to ensure the balance between cost and performance

Which is the potential lightweight material?GLOBAL LIGHTWEIGHT AUTOMOTIVE CONFERENCE 2014, May2014, LONDON

COMPOSITES MARKET GROWTH BASED ON ROW MATERIAL & MANUFACTURING PROCESSES COSTS

FIBER REINFORCED PLASTICS (GFRP & CFRP) ARE USED IN STRUCTURAL PARTS

RELATIONSHIP BETWEEN AUTOMOTIVE OEMs AND COMPOSITE MAIN PLAYERS

JUST AN EXAMPLE

McLaren F1

Alfa Romeo 4C

IN COMPOSITES THERE IS ANOTHER SPECIFIC RACE

Sheet

moulding

compound

VISUAL PIECES

Resin transfer

moulding

Pre-preg or

infusion + autoclave

Compression

moulding

Injection

moulding

NON VISUAL PIECES

Compression moulding or

Sheet moulding compound

MECHANICAL COMPONENTS

Group

Stamping dies design and

manufacturing for integral solutions

Design and manufacturing of systems for safety and ergonomics

Design and manufacturing of components for

weight reduction & driving efficiency

Development and manufacturing of

innovative solutions in renewable

energies

1963 1982 2010 2005

BATZ Automotive BATZ Energy

Customers

Group

Worldwide and diversified turnover at the main OEMs

2013 year

Figures 2013 year

BATZ GroupTotal Turnover 222.38 M€

Total Workforce 1.448

Group

Weight reduction, performance optimizing and recyclability in structural parts

Frontend carrierIMC (Injection Moulding Compound), 12 mm

Cockpit carrierGMT (Glass Mat Thermoplastic) GLF (Glass Long Fiber), 25 mm

Floor panelsSMC (Sheet Moulding Compound)

CO2 emissions reduction, optimizing aerodynamic and paneling components

Engine undertray

Deflectors

Body undertray

SMC (Sheet Moulding Compound)

PLASTIC- METAL HYBRID SOLUTIONS

Expertise in Weight Reduction

DESIGN OPTIMIZATION

PEDAL BOX

Through material and technology

The use of advanced materials like polymers in substitution of highly loaded steel parts

requires a careful adaptation of the geometry to maintain the requested performance

Previous VW Polo Pedal Box

Current VW Polo / Audi A1 / … Pedal Box

Several Steel Parts Stamped and Welded together

One Single Polymeric Part (PP+30GF)

Weight BRACKET 1.520 g Weight BRACKET 650 g (-58%)

Cost PEDAL BOX (X) Cost PEDAL BOX (X) – 22%

Expertise in Weight Reduction

DESIGN OPTIMIZATION

PEDAL BOX

Same PPGF material + Optimized Process & Geometry

The use of advanced materials like polymers in substitution of highly loaded steel parts

requires a careful adaptation of the geometry to maintain the required behaviour.

Current AUDI A1 Pedal Box

Case Study – Topological Optimization

Weight BRACKET 650 g Weight BRACKET 495 g (-24%)

Cost BRACKET (Y) Cost BRACKET (Y) – 19%

WIT Reinforcement for Critic Areas

Conventional injection molding

Expertise in Weight Reduction

DESIGN OPTIMIZATION

Weight BRACKET

495 g

-24%

Weight BRACKET

650 g

-58%

Weight BRACKET

1,520 g

Reference

Materials, Process & Geometry optimization

MATERIALES COMPUESTOS EN

AUTOMOCIÓN,

¿POR QUÉ, CUÁNDO, CÓMO y DÓNDE?

• L i g h t e r

• C l e a n e r

• B e t t e r

REFERENCES

Meeting your challenges

Thanks a lot for your attentionjintxaurbe@batz.es