Composites & automotive mass production: Any convergence ...
Transcript of Composites & automotive mass production: Any convergence ...
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composites & automotive mass production: Any converge nce of interests ?
Journées techniques "Le 3ème Round des composites"
Hôtel Palladia - Toulouse
Stéphane JOLY 31 Janvier 2019
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
PSA Groupe: 6 Brands = Citroën, DS, Opel, Peugeot, Vauxhall & Free 2 Move
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Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL 3
PSA Groupe: Production sites: Near our customers worldwide
Site de production automobile
(en joint-venture, en coopération ou partenariat)
Site de mécanique, fonderie
(en joint-venture, en coopération ou partenariat)
Site d’assemblage
Centre R&D
Centre de pilotage et d’expertises
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
PSA Groupe: …& especially in Europe
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Site de production automobile
(en joint-venture, en coopération ou partenariat)
Site de mécanique, fonderie
(en joint-venture, en coopération ou partenariat)
Site d’assemblage
Centre R&D
Centre de pilotage et d’expertises
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Amérique Latine
175 257
-15,0%
Europe
3 106 160
+30,6%
Moyen-Orient Afrique
291 998
-52,8%
Eurasie
15 288
+0,50%
IndePacifique
26 479
+1,6%
ChineAsie du Sud Est
262 583
-32,2%
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PSA Groupe: 2018, commercial results - 3 877 765 vehicles sold dans les 6 régions du Groupe
+6,8% 3 877 765
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry
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This is not what we call industry
But there are composite materials on this racing car
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry
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This is what we call industry
3,9M vehicles / year⇒ 13 000 vehicles / day (300 days /year)⇒ 18 000 tons of materials / dayBut only few kg of composite materials / vehicleWhy that ?
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in PSA Groupe: Our present needs
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What are the needs for composite materials introduction on our cars ?
Body in white weight reductionBattery boxHydrogen tanks
http://www.nuancierds.fr/DT%20toits.htm
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry
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What are those composite materials ?
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
State of the art: SMC materials + compression molding
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1982: Citroën BX
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
State of the art: SMC materials + compression molding
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Glass fiber SMC semi-structural part: Tailgate innerFrom 2011 up to now
High production capacity: 1 part / mnAffordable material cost: ~3 € / kgDensity: From 1,70 up to 1,95Assembly: gluing, screwing
DS7 tailgate: exploded view
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in PSA Groupe
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Body in White (BiW), composite part:Glass fiber SMC spare wheel well
Peugeot 3008 1.2 Pure Tech (2016):m = 1406kgmBiW = 312kg (+168kg openings)
Strong will to reduce BiW weight
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry
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No carbon fiber
composite materials ?
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry: BMW Corner stones
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2016: Serie 7, mainly steel2013: i3, mainly carbon reinforced polymers
2019: i5, ???
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry: Volvo Polestar 1 (2019)
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Composite parts:• Rear tablet• Rear floor• Tunnel reinforcement• Under seats, rear beam
Not so much and let’s confirm on the car in the street
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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What are the major challenges ?
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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The car volume is an input of the design stage
=> Compare materials at iso volume
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges : Strength comparison
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Carbon fibers semi-products overpass steel strength
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Glass fiber UD tapes: acceptable performance
Glass fiber fabrics reinforced polymers show between half and 1/3 of steel strength
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But their cost per volume is more than twice steel cost
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges: Stiffness comparison
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Introduction of continuous glass fiber reinforced
polymers ?
• Glass composite vs Steel • At iso-volume• Materials are at iso-cost
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But stiffness divided by 5 to 10
Materials cost in the part: x5 to x10
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges : cost reduction
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Introduction of continuous carbon fiber reinforced
polymers
• Carbon composite vs Steel • At iso-volume• Cost is increased by 2 to 4
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Stiffness is divided by 2=>
Materials cost in the part: x4 to x8
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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The major challenge is raw materials cost reduction
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials cost reduction: FORCE Project
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Sept. 2018: Pilote line available• Mesh size 12K * 10• Production capacity: 2 tons /year• Temperature max: 1150°C
Partners : IRT Jules Verne, CANOE, Groupe PSA, Arkema, Mersen, Plastic Omnium, Chomarat, Renault, Decathlon, Total, Faurecia, Stelia Composites, TembecBudget : 18 M€Duration : 2014 - 2019
Objectives :• Low cost carbon fiber < 8€/kg• E=250GPa• σ~2500 MPa
Still a factor 2 to gain
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials cost reduction: Zero material waste
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Objective: zeromaterial waste
Usage coefficient on a part must be close to 100%
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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Major challenge: Production capacity, cycle time
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Organosheets + compression molding + overmolding
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COMPOSTAMP project: Complex & large part:- ribs (on both sides)- a tunnel- embossed areas- Overmolding- m = 1915 g, S = 530 x 850 cm²
Cycle time: 1 part every 63 seconds=> Materials and process are ready for mass product ion (material cost too high > 6€/kg)
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Dry fibers + resin injection: C-RTM
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Fast RTM project demonstrated:• a material availability
• Arkema Acrylic resin• Hexion Epoxy resin
• an injection process robustness• cycle time of 2 mn / part
⇒ Fast FORM project(2016 – 2021)
It has also demonstrated that preparing a preform in 2mn / preform
is not possible today !!!
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in the automotive industry: Composite process
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Filament winding
Dry plies preforming (*)
Fiber
length
(mm)
0.5 to 20
25 to 50
Endless
1 2 5
Compression
molding
Injection
molding
Thermo
stamping
C-RTM RTM-TP
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LP-RTMHP-RTM
Automated Fiber/Tape Placement
Fiber
projection
Autoclave
Cycle time
(mn)
Part
complexity
Structural applications
Legend:
C-RTM, HP-
RTM, LP-RTM,
RTM-TP:
Compression,
High Pressure,
Low Pressure,
Thermo
Plastique,
Resin
Transfer
Molding
TP & TS
TSTP
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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Major challenge: Multi-materials assembling
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges : Multi-materials assembling
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Assembling steel, aluminum and composite materials with the same tool: electrical welding point
Technology validation on-going
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Composite materials in automotive industry: Major challenges
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Other challenges
Composite materials agings: 15 years, 250 000 km- Test standards to define
Composite materials repairing- Protocole to define- Know how to spread
Composites et production automobiles de masse: Convergence d’intérêts ?Vélizy / DQI/DCHM/PMXP/PMD/MVEL
Conclusion
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Long is the road
Thank you for your attention