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Next-Generation Sandwich Steel Revolutionizes Transportation Industry

Doug Cox President & CEO

Fabien Ebnoether Chief Engineer

Special acknowledgements: Prof. Dirk Mohr (Ecole Polytechnique/MIT)

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Lightweight Steel

Steel industry challenge:

• Corporate Average Fuel Economy (CAFE) demanding lightweight solutions

• Growing use of aluminum - Ford announces aluminum F-150

Solution:

CellTech is a solution provider:

• Steel industry enabler

• Optimize all-steel sandwich structure for transportation applications

• Low cost sandwich manufacturing process

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Sandwich Technology│ generic

Face sheet

Face sheet

Lightweight core material

Sandwich structure

t 2t 4t sheet

sandwich

sandwich

Relative bending stiffness

1 7 37

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Sandwich Technology│ markets Rail

Military

Sports

Solar

Trucks

Construction

Buses

Automotive

Marine

Ships

Containers

Aerospace

Elevators

Satellites

Furniture

Truck Trailer

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The Company│ history

• Founded in 2004 in San Diego, USA

• An engineering technology company

• Focused on light weighting metal for sandwich applications

• 2005 to 2009 development with automotive companies - recession

• 2009 began development for the truck trailer industry

• 2013 commercialized products for the truck trailer industry

• 2014 commited to re-enter the automotive industry

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The Company│ objectives

• Maximizing the efficiency of metal

• Develop a mass producible all-metal sandwich

• We engineer our technology to create the optimized material for a specific industry application

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Application development

Application requirements &

objectives

Computational modeling

Prototype development

Testing &

validation

Commercialization Final design

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Application development (2)

Application requirements &

objectives

For example: Physical requirements

• Weight • Corrosion

Mechanical requirements • Bending • Shear • Compression • Puncture • Durability

Objectives • Cost • Manufacturing • Repair

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Application development (3)

Application requirements &

objectives

Computational modeling

1. Basis material characterization

test program plasticity model fracture model

validation material card

calibration

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Application development (4)

Application requirements &

objectives

Computational modeling

1. Basis material characterization

2. Virtual engineering & optimizing Considering ductile fracture during forming

Damage 0 1

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Application development (5)

Application requirements &

objectives

Computational modeling

1. Basis material characterization

2. Virtual engineering & optimizing

3. Development of material models Macroscopic constitutive modeling for shell elements

1

2

3

4 n

IP #1

IP #2

IP #3

virtual experiments on microstructure macroscopic constitutive model

sandwich

composite shell element

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Application development (6)

Application requirements &

objectives

Computational modeling

Prototype development

Compression test Puncture test

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Application development (7)

Application requirements &

objectives

Computational modeling

Prototype development

Bending test

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Application development (8)

Application requirements &

objectives

Computational modeling

Prototype development

Testing &

validation

Bulge test: semi-trailer side wall AAR test stage 1) 14,400lbs uniform pressure 2) 28,800lbs uniform pressure → Passed both stages

1) 2)

Test

jig

Air b

ag

Moc

k up

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Application development (9)

Application requirements &

objectives

Computational modeling

Prototype development

Testing &

validation

Bulge test: semi-trailer swing door AAR test stage 1) 20,400lbs uniform pressure 2) 35,700lbs uniform pressure → Passed both stages

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Lightweight Sandwich Product Portfolio

CellTech Sheet • 4 metal layers • Thin sandwich material

(≤ 3mm) • Brazing or adhesive • Excellent formability • Substitute for sheet metal

• 3 metal layers • Thick sandwich material

(> 3mm) • Adhesive • Limited formability • Used as flat panel

CellTech Panel

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CT Sheet│ formability

No delamination

Initially flat sandwich sheet

Deformed sandwich sheet

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CT Sheet│ formability (2)

Stamping test of an upper A-pillar inner reinforcement part

• Prototype samples proven to be stampable

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CT Sheet│ weldability

Process parameters: • AC welding (60Hz) • 11.8kA for 20 cycles • Force about 2.5kN

5mm

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CT Sheet│ structural member

• Energy absorption 70% higher for the same weight!

0

5000

10000

15000

20000

25000

0 20 40 60 80 100 120Displacement [mm]

Axi

al fo

rce

[N]

sandwichconventional

sandwich conventional

Axial crushing

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CT Sheet│ structural member (2)

0

2000

4000

6000

8000

10000

12000

14000

0 10 20 30 40 50 60 70Deflection [mm]

Forc

e [N

]

sandwichconventional

conventional

sandwich

• Energy absorption 120% higher for the same weight!

• Sandwich sheets can carry much higher in-plane compressive loads before and after buckling!

Bending

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Lightweight sandwich material for flatter industry applications • High stiffness per weight

• Cost-efficient mass production

• Ability to use low cost galvanized steel sheets

• Bonding with a high performance aerospace grade structural adhesive

• 100% recyclable to be environmental friendly

CT Panel

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CT Panel│ bendable

Curved along width direction (radius = 1.0m)

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CT Panel│ bendable (2)

no delamination

90° angle bend along width direction using a brake press

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CT Panel│ corrosion

Bare galvanized steel (G90)

G90 + corrosion protection system

initial

1,000hrs salt spray (ASTM B117)

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CT Panel│ application

Truck Trailer parts: • Doors (swing and roll-up) • Side walls • Roofs • Floors

Manufacturing partner

Construction

Truck Trailers

Containers

Early Adoptors Immediate Opportunity

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CT Panel│ application (2)

“CellTech is a revolutionary material for the trailer industry.”

VP-engineering

Mid America Truck Show (March 2013)

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CT Sheet & Panel│ considerations

• Type and gauge of metal, metal coatings, bonding method

• Low cost manufacturing process to deliver product

economics

• Most suitable industry applications

• Strategic partner(s) for joint application development

• Strategic partner for manufacturing

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CellTech & Steel Industry

• We are committed to help steel become a low cost, light weight solution; outperforming other metals and composite materials.

• With the proper steel, correct sandwich design, manufacturing efficiencies and the appropriate selected industry application = Steel Can Become The Ultimate Light Weight Solution.

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Q & A

Thank you!