Automotive Composites Group...Automotive Composite Group Established by the Automotive Council’s...
Transcript of Automotive Composites Group...Automotive Composite Group Established by the Automotive Council’s...
COMPOSITES LEADERSHIP FORUM
Automotive
Composites Group: Henry Sarel-Cooke
Automotive Compositives Group Chair
GKN Wheels & Structures
Nov 2018
Composites Leadership Forum 1
Automotive Composite Group
Established by the Automotive Council’s
Manufacturing Group and the CLF. The
Group is chaired by Henry Sarel-Cooke of
GKN.
Aim: “to facilitate development of UK
technology capability and supply chain
capacity to deliver high productivity
manufacturing of globally competitive, higher
volume composite structures and
components”.
The ACG has set targets, mapped out the
supply chain development required and is
now seeking to fill gaps that could restrict
future development.
It is working with Government and funding
bodies to identify funding mechanisms to
facilitate this.
Participants include:
– McLaren
– JLR
– Nissan
– Williams
– GKN
– Solvay
– Gordon Murray Design
– Nippon Electric Glass
– Nottingham University
– National Composites Centre
– Dept for International Trade
– Innovate UK
– APC
2Composites Leadership Forum
Lightweighting
Drivers
CO2 targets & push for improved air
quality drive increased energy efficiency.
Weight reduction lowers CO2 in ICE &
engines & brakes can also be smaller.
Lightweighting counters weight increase
due to greater inclusion of vehicle safety,
comfort and entertainment content.
In PHEVs and BEVs, batteries and
components make vehicles heavier than
ICE vehicles. Lightweighting also extends
range.
Challenges
Life cycle considerations pose challenges
for new materials and manufacturing
choices, often narrowing options
Steep CO2 reductions will require further
much more than incremental innovation in
weight reduction. Targets have been set to
drive innovation in vehicle materials,
design and manufacturing.
Weight reduction should be achieved
without unreasonable cost, safety or
emissions reduction.
Car 2015 2025 2035
Conventional vehicle weight Baseline -10 -> -15% -25 -> -30%
xEV weight Baseline -5 -> -7.5% -25 -> -30%
Recyclability 85% 85% 95%
Targets
CLF ACG Areas of Focus
• Delivery of the composites part of the Auto Council Light weighting
roadmap:
– ISCF Challenge fund bid ‘Materials for Future Mobility’ contains:
– Manufacturing Development - Composites Large Scale Project: Preforming
development led by HVMC, consortium including Bentley, Ford, JLR,
McLaren, Nissan, GKN, Gestamp.
– Materials Development – National Composites Materials Centre: Focused
on materials supply chain development.
• Engagement with more Auto OEMs and Tier 1s.
• Workshops to develop Innovate UK and APC collaborative
proposals.
• Supply chain mapping and analysis.
Auto Council Light weighting Roadmap
Lightweighting Roadmap - Composites
Modelling tools enable complex multi-material load-bearing structures.
High volume structural - Composites use where most valuable e.g. weight saving in unsprung mass and suspension. Automation to decrease takt timeHigh volume panels - Lightweight structural
composites increasing role. Roof panels a priority for lighter materials.
Powertrain - Selective lightweighting as process and materials develop e.g. conrods and propshaft.
Batteries - part consolidation & integrated features with lower weight. Process development for higher volume. Longer term batteries more readily integrated into vehicle structure
Seat for light-weighting if takt time reduced.
Embedded electrical systems
Reducing the takt time unlocks new applications at mid & high volume. Requires preforming & automation to increase speed, reduce waste and increase accuracy.
Joining - Development of mono-material processes for multi-materials such as multi-point joining (e.g. thermoplastic welding), bonding (e.g. quick cold cure resins), mechanical joining.
Surface treatments enable enhanced component performance such as thermal, hardness, low friction, aesthetics.
Next Generation Composite Manufacturing
(Composites Large Scale Project – CLSP)
Contact : [email protected]
Composite production projects underway
Programme Mission
Identifying, developing and transforming the UK supply chain for competitive high volume manufacturing of composites for automotive applications and allied markets.
Auto Council TARGET 2025AVERAGE weight reduction of existing
systems of 15%
ACG TARGET 2025TYPICAL on-cost not to exceed £5 per
kg of weight saved
ACG TARGET 2025EXISTING vehicle end of life recycling
> 85% recyclability
ACG TARGET 2025TYPICAL takt time 60s
Global automotive composite prediction (Persistence Market Research)
UK automotive composite prediction (DIT)
Upper
Lower
POTENTIAL MARKET IMPACT £3.5 bn p.a. by 2030
UK supply chain globally competitive
In place for window of opportunity
POTENTIAL MARKET OUTCOMES £3.5 bn p.a. by 2030
UK supply chain globally competitive
In place for window of opportunity
2018 2019 2020 2021 2022
Technology development:• Feasibility studies• Technology maturation• Supply chain MRL mapping• Cluster facilitation
£98.9m Total
Programme Value
(FY 18 – 22)
Capability Demonstration (mid TRL/MRL) including:• Nascent supply chain • Technology visibility in
application • Breadth of technical capabilities
Enabling capabilities e.g• Automation • Quality Assurance• CAE & Modelling
Programme Summary : Cost Breakdown
Scale up projects:• OEM & Tier 1 led • Co-funded through
Advanced Propulsion Centre support
Fibres & Precursors
Matrix & Formulation
Recycling/Environment
Composite Materials Support
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Sizing/ Surface/Additives
Inter-mediates
Part Production
Integration/ Assembly
EquipmentProducers
TIER2/TIER1/OEMs Product/Process TRL
5-10 yearsFor Aero/autoadoption
New Material TRL
5-25 yearsFor new
materialsinnovation
Currently supported by HVMC, ATI, APC, Innovate UK, CIMComp
Currently supported by (over subscribed) Innovate UK call for all materials. Strategic support proposed through National Composite Materials Centre (NCMC).
Materials development -key to optimising composite product development and increasing GVA.
Next Generation Composite Materials
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National Composite Materials Centre
CPI Formulation
Centre
NCC & AMRC
Preforming
AMRC Textiles
NCC & AMRC
Braiding
NIACE Textiles
FibrelineNew resin chemistry
Prepreg
DaresburyMultiscale modelliing
CMC
Industrial Steering Board
Blue spheres =Existing spokes
Red spheres = start-up and sustainment of new spokes over 5 years
Collaborative R&D Programme
University R&D Programme
HVM Catapult
Iteration to ensure material development facilitates process and product development
Economic and Social Impact
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Composites Leadership Forum
Potential UK Opportunity Post 2020
From 2020 onwardsUK Car
production (SMMT
estimate) 2020
Supercar (S)
Luxury (F)54%
(1.13M)
SUV (J)
Multi-
purpose (M)
Small (B)
Medium (C)
Large (D)
26%
(546k)
20%
(420k)
5%
(700k)
26%
(3.3M)
2.1M 14M
Steel &
Thermoplastic
Composites
EU Car
sales (EU28
actual) 2011
69%
(10M)
Exec (E)
Aluminium & Thermoset
Composites
Aluminium
& SteelAluminium,
Steel & TP
Composite
Passenger Car Market Segments
UK produces
high proportion
of heavier/
expensive cars
“lightweighting
opportunity”
Mini (A)
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Thank you for your time
Composites Leadership Forum 14
www.compositesleadershipforum.com