Lightweight FRP solutions from
BENTELER-SGL
Economic lightweight design on structural components –
the right material – in the right position – with the right technology Global Automotive Lightweight Materials Detroit 2016
23/08/2016 Robert Hü1er 2
Global Automotive Lightweight Materials Detroit 2016
Agenda
Introduction BENTELER-SGL (BSGL)
Footprint BENTELER Automotive in North America
Examples for actual FRP applications
Reasons for a decision for FRP applications
Main drivers of cost structure of FRP components
Outlook 2020 and main drivers to reach a competitive cost structure
Development example: FRP rear wall in economic lightweight design
Summary
23/08/2016 Robert Hü1er 3
Global Automotive Lightweight Materials Detroit 2016
Agenda
Introduction BSGL
Footprint BENTELER Automotive in North America
Examples for actual FRP applications
Reasons for a decision for FRP applications
Main drivers of cost structure of FRP components
Outlook 2020 and main drivers to reach a competitive cost structure
Development example: FRP rear wall in economic lightweight design
Summary
Global Automotive Lightweight Materials Detroit 2016
Introduction BENTELER-SGL
Plant Ort
Plant Ried
high volume production (10.000 sqm)
HQ, small vol. production, R&D, technical center
Berlin
VIENNA 1 2
Paris
Berlin London
1. Ried im Innkreis, Austria 2. Ort im Innkreis, Austria
50% 50%
Global Automotive Lightweight Materials Detroit 2016
Introduction BENTELER-SGL
Carbonfiber Tex,les Braiding Prepregs
Mass Production Plant & Production Engineering
Simulation & Test
BENTELER-SGL is able to apply the fiber Know-How of the SGL Group combined with the High-Mass-Production Know-How at BENTELER Automotive.
BENTELER-SGL is a full service provider to the automotive industry.
23/08/2016 Robert Hü1er 6
Global Automotive Lightweight Materials Detroit 2016
Agenda
Introduction BSGL
Footprint BENTELER Automotive and BSGL in North America
Examples for actual FRP applications
Reasons for a decision for FRP applications
Main drivers of cost structure of FRP components
Outlook 2020 and main drivers to reach a competitive cost structure
Development example: FRP rear wall in economic lightweight design
Summary
Global Automotive Lightweight Materials Detroit 2016
Footprint BENTELER Automotive and BSGL in North America
1. Auburn Hills, MI *2001 – Reg. HQ, EO
2. Grand Rapids – Hagen Drive, MI *1979 – Plant, EO
3. Holland, MI *2010 – Plant, EO
4. Kalamazoo, MI *1979 – Plant, EO
5. Goshen, IN *1990 – Plant
6. Spartanburg, SC *2005 – Plant (JIT), Plant
7. Hermosillo, Mexico *2000 – Plant
8. Saltillo, Mexico *1995 – Plant (JIT)
9. Puebla Assembly, Mexico *1992 – Plant, SO, EO
Puebla Assembly, Mexico *2008 – Defense (Plant)
10. Puebla Stamping, Mexico *2010 – Plant
Global Automotive Lightweight Materials Detroit 2016
Footprint BENTELER Automotive and BSGL in North America
As a full service supplier, BENTELER Automo,ve u=lizes extensive engineering experience, manufacturing know how and vast knowledge of Steels, Aluminum and FRP materials to provide
an op=mized single or mul= material lightweight solu=on to our customers.
23/08/2016 Robert Hü1er 9
Global Automotive Lightweight Materials Detroit 2016
Agenda
Introduction BSGL
Footprint BENTELER Automotive in North America
Examples for actual FRP applications
Reasons for a decision for FRP applications
Main drivers of cost structure of FRP components
Outlook 2020 and main drivers to reach a competitive cost structure
Development example: FRP rear wall in economic lightweight design
Summary
Global Automotive Lightweight Materials Detroit 2016
Examples for actual FRP applications
Visible Carbon Design Parts Hang-on Performance Parts
Structural components/modules Chassis components
(e.g. Trunk Lid Porsche GT3)
(e.g. Leaf Spring Volvo XC90) (e.g. Rocker Lamborghini Aventador)
(e.g. Sideblade Audi R8)
Responsibility level from „build to print“ to „development responsible“ (product-‐&process design)
23/08/2016 Robert Hü1er 11
Global Automotive Lightweight Materials Detroit 2016
Agenda
Introduction BSGL
Footprint BENTELER Automotive in North America
Examples for actual FRP applications
Reasons for a decision for FRP applications
Main drivers of cost structure of FRP components
Outlook 2020 and main drivers to reach a competitive cost structure
Development example: FRP rear wall in economic lightweight design
Summary
Global Automotive Lightweight Materials Detroit 2016
Current reasons for a decision for FRP applications
Design reasons (e.g. visible carbon design)
But only a very few FRP projects (e.g. BSGL leaf spring) will be realized because of economic reasons.
Specially for high volume projects, new ways and approaches have to be considered!
Performance reasons (e.g. freedom of geometrical design, maximum lightweight design)
Political/strategic reasons (Management decision for FRP solution, pilot project)
economic decision = cost compe==ve includes the customer specific weight saving bonus (e.g. 10€/kg)
23/08/2016 Robert Hü1er 13
Global Automotive Lightweight Materials Detroit 2016
Agenda
Introduction BSGL
Footprint BENTELER Automotive in North America
Examples for actual FRP applications
Reasons for a decision for FRP applications
Main drivers of cost structure of FRP components
Outlook 2020 and main drivers to reach a competitive cost structure
Development example: FRP rear wall in economic lightweight design
Summary
Global Automotive Lightweight Materials Detroit 2016
Current cost structure of structural FRP components
2020 2016
45 % Production
process
55% material
Cos
t per
par
t
40-60 €/kg
§ Single or partly automated process steps
§ Manual load and unload § RTM cycle time 15-20min. § Partial rework of milled edges § No chaining of process steps § Expensive pre- and post-processes
§ C-fiber price 15-16€/kg § Semi finished material (NCF, woven
fabric) 23-25€/kg § 50% material usage § Matrix system 4-5€/kg § diff. additional add on parts and
core materials
§ Mostly designed for metals (Steel, Aluminum …)
§ Low volume projects (<20k sets/à) § Max. lightweight design § High degree of security (over design)
level because of lack of experience/know-how
23/08/2016 Robert Hü1er 15
Global Automotive Lightweight Materials Detroit 2016
Agenda
Introduction BSGL
Footprint BENTELER Automotive in North America
Examples for actual FRP applications
Reasons for a decision for FRP applications
Main drivers of cost structure of FRP components
Outlook 2020 and main drivers to reach a competitive cost structure
Development example: FRP rear wall in economic lightweight design
Summary
Global Automotive Lightweight Materials Detroit 2016
Outlook 2020 and main drivers to reach a competitive cost structure
2020 2016
45 % Production
process
55% material
Cos
t per
par
t
40-60 €/kg
35-40% Produc=on process
~ 20 €/kg
60-65% material
Cos
t per
par
t
§ Automated chained process line § Reduction of pre- and post-
processes § Processes to work directly with the
fiber into the tool § Reduction of cycle time § No manual rework
§ C-fiber price 12-13€/kg § Focus on material mix (G- & C-fiber) § >85% material usage § Matrix system 3-4€/kg § reduction of additional add on parts
and core materials
§ Single or partly automated process steps § Load and unload manual work § RTM cycle time 15-20min. § Partly rework on milled edges § No chaining of process steps § Expensive pre- and post-processes
§ C-fiber price 15-16€/kg § Semi finished material (NCF, woven fabric)
23-25€/kg § 50% material usage § Matrix system 4-5€/kg § diff. additional add on parts and core materials
§ Mostly metal design § Low volume projects (<20k sets/à) § Max. lightweight design § High degree of security level because on lack on
experience/know-how
§ FRP design § load path design know how § High volume projects (100k sets/à) § Max. economic lightweight design § Reduction of security level to
maximize potential of FRP design
23/08/2016 Robert Hü1er 17
Global Automotive Lightweight Materials Detroit 2016
Agenda
Introduction BSGL
Footprint BENTELER Automotive in North America
Examples for actual FRP applications
Reasons for a decision for FRP applications
Main drivers of cost structure of FRP components
Outlook 2020 and main drivers to reach a competitive cost structure
Development example: FRP rear wall in economic lightweight design
Summary
Economic FRP lightweight design Compe,,ve metal design
Global Automotive Lightweight Materials Detroit 2016
Development example: FRP rear wall in economic lightweight design
§ 2-shell design § monolithic material § 4,8kg @ 45€/part
Material Design
Global Automotive Lightweight Materials Detroit 2016
Development example: Explanation of the FRP development circle
Input to the Development Circle: § Knowledge of part properties § Experience of comparable
applications § Experience of FRP design § Know-How to work out the load
path in the component
Input to the Development Circle: § Knowledge on the whole process
chain § Experience in automation and
chaining of single process steps § Know-How of FRP specific
properties for the different processes
Input to the Development Circle: § Requirments and load cases on the
component § Full vehicle competence § Openness to new ways and new
approches
Input to the Development Circle: § Material characterisation § Behavior of the different material
combinations § Requirement on fiber and resin
Development Circle
Placeholder
Process Design Cu
stom
er Rela=
onship
Part Design
A economic compe,,veness of FRP is possible, if all 4 segments are considered during the development process!
Output: § Identification of the necessary
process steps § Concept for a most efficient
process chain § Assessment of maturity level of
the needed processes and definition of development actions to reach the required level
Global Automotive Lightweight Materials Detroit 2016
Development example: FRP rear wall in economic lightweight design
Output: § Reviewing and adoption of
requirments manual § Definition of new standards based on
the experiances out of the dev. Phase § Support on full vehicle questions
Output: § Material characterisation § Testing of draping and infusion
behavior § Curing time optimisation
Placeholder
Process Design Cu
stom
er Rela=
onship
Part Design
Material Design
Output: § Identification of position and
dimension of load parth § Positive simulation result § Amount of material incl. layup plan
Global Automotive Lightweight Materials Detroit 2016
Development example: FRP part concept evaluation and definition
G-‐fiber
UD-‐tapes
C-‐fiber
woven / NCF
RTM
prepreg-‐pressing
Towpreg fiber laying
winding
2 shell
FRP + AL
fiber material
CF-‐SMC
recycling fleece
Fiber placement
WP
TFP
load path
reinforcem
ent
target: 20€/kg
general concept surfa
ce
reinforcem
ent
Global Automotive Lightweight Materials Detroit 2016
Development example: FRP rear wall in economic lightweight design
TFP 12-head-equipment à Carrier fleece in the line à Separated stacks ready
provided
Fiber placement + Stack handling incl. resin and core
application
Standard wet press cell
Robotic milling cell
Montage cell if needed to mount
add on parts
Cost compe,,veness by: • Automa=on • Standardisa=on • High volume produc=on
Economic FRP lightweight design Compe99ve metal design
Global Automotive Lightweight Materials Detroit 2016
Development example: FRP rear wall in economic lightweight design
§ 2-shell design § monolithic material § 4,8kg @ 45€/part
§ sandwich design § Load path optimized § 3,2kg @ 62€/part
BENTELER-‐SGL can offer cost compe==ve FRP solu=ons!
23/08/2016 Robert Hü1er 24
Global Automotive Lightweight Materials Detroit 2016
Agenda
Introduction BSGL
Footprint BENTELER Automotive in North America
Examples for actual FRP applications
Reasons for a decision for FRP applications
Main drivers of cost structure of FRP components
Outlook 2020 and main drivers to reach a competitive cost structure
Development example: FRP rear wall in economic lightweight design
Summary
the right material – in the right position – with the right technology
2.) Core-process-know-how for short cycle time and technologies to reduce the pre- and post-processes – lean process design
Global Automotive Lightweight Materials Detroit 2016
Summary
To reach the target of ~20€/kg, the whole FRP approach has to be changed. Starting with the definition of the best part concept, the approach of the part design has changed into design along the advantages of the different fiber materials (e.g. expensive C-fiber in load path direction, G-fiber in less loaded areas) to design the best economic lightweight part. On the process design side, there has to be a process chain which can combine the optimized fiber combination, fiber usage and a maximum process chaining and automation for the main process steps.
Summary: BSGL can reach the target - focus on two major aspects: 1.) Deep understanding of the requirement of the component in combination with the knowledge of the material properties – load path oriented design
Global Automotive Lightweight Materials Detroit 2016
Economic lightweight design on structural components
Robert HüQer Director Sales-‐ & Program Management ___________________________________ Benteler SGL Composite Technology GmbH Fischerstraße 8 A-‐4910 Ried im Innkreis P: +43 7752 82500 569 F: +43 7752 82500-‐3969 M: +43 664 60919-‐569 Mail: robert.hue1er@benteler-‐sgl.com www.benteler-‐sgl.de
Thank you for your attention!