Mandatory Checkpoints for a Higher Composite Market Share in Automotive / 03 / 2017

Transcription

1 Mandatory Checkpoints for a Higher Composite Market Share in Automotive guillaume.chambon@faurecia.comrld - 15 / 03 / 2017

2 Agenda 1 Faurecia Composite Technologies 2 Where do composites stand? 3 Acting on the Composite value chain 4 Conclusion 2

3 1 Faurecia Composite Technologies 2 Where do composites stand? 3 Acting on the Composite value chain 4 Conclusion 3

4 Faurecia Clean Mobility Composite Technologies, a division of Faurecia s strategy in Clean Mobility Building blocks towards Cleaner Solutions A global leader in its 3 activities Real Time Data Fuel Cell Technology Energy Recovery for Electrical Vehicle Lightweight composite solutions #1 worldwide in mechanisms & seats structure #3 worldwide in complete seats Exhaust Energy Recovery Innovations Lightweight Innovations #1 worldwide interior vehicle Air Exhaust Quality Innovations: Heated Energy Catalyst, ASDS, Turbo Recovery Gas, EGR Innovations Lightweight Innovations #1 worldwide in emissions control technologies CV off-highway High Horse Ppwer Passenger cars emission control CV on-highway Current business Traditional portfolio Innovations CV Off-highway and HHP Adjacent clean solutions for EV 4 Drive the transformation of the global Mobility Value Chain towards Cleaner Solutions

5 Faurecia Composite Technologies A transversal center of expertise for Faurecia Group activities Customers Body EV Seating Interiors Clean Mobility o Semi-structural & Structural o Crash resistance & absorption o Stiffness & Rigidity o Underbody / Aero & Skid Shields o Acoustic / NVH o Impact resistance o A-class body o Closures o Rear/side crash test o Functional integration o A-class o Battery Protection o Semi- & Structural o Crash absorption o Painting o Heat resistance o Functional o Fnct. integration integration o Seat Structures o Luggage crash o Aspect (B-side) o Acoustic / NVH o Functional integration o Cross-car Beam o Crash o Heat Shields o Temp. resistance o Acoustic / NVH o Functional integration o H2 tanks 5

6 1 Faurecia Composite Technologies 2 Where do composites stand? 3 Acting on the Composite value chain 4 Conclusion 6

7 Market trend for mass market General understanding Performance + Cost penalty acceptance* CO 2 emissions No market New achievable market - Time No market * Exact figures depending on : OEM Product Place in the vehicle Production volume (incl. tooling influence) 2 /kg saved 3 /kg saved Time Potential for more application driven by better cost penalty acceptance 7

8 BMW case study BMW i3 BMW i8 BMW 7-series Oct 2016: BMW announces they will limit the use of CF, turning instead to lightweight steel to keep profit. CF Life Module (BIW / Life Module) Aluminium Drive Module BIW combining steel / aluminum / CFRP 16 CFRP parts Life Module Drive Module Towards an architecture including composites just-where-needed instead of a complete BIW in composite 8

9 Composite Competition Metal : Magna Example Ultralight door architecture with 42.5% weight savings Extensive use of aluminum Contributions in the area of molding techniques and polymers represented approximately 7% of the total mass reduction The target in terms of cost was approximately $5 per pound and we came in at $2.59 per pound Ultralight Door Module - Magna Composite application in mass market is not established 9

10 1 Faurecia Composite Technologies 2 Where do composites stand? 3 Acting on the Composite value chain 4 Conclusion 10 JEC World

11 Status on composites The composite value chain Mid term Target for composite : -20 to -40% on total cost vs today Levers Raw material Process Product Assembly Engineering Expectation Lever - Reduce raw material price - Reduce semifinished products - Material compliance with quick processes - Tailored mechanical performance - Speed - Reduce waste - Reduce scrap - Reduce post molding activities - Automation - Tailored design - Function integration - Hybrid assembly - Speed - Reliability - Reduce trial number - Increase material knowledge & accuracy - Eng. & Devlt. time reduction - Global costing approach Mandatory to act on multiple levers of the composite value chain 11 JEC World

12 1 Faurecia Composite Technologies 2 Where do composites stand? 3 Acting on the Composite value chain Raw material Process Product Assembly Engineering 4 Conclusion 12

13 Material Carbon price reduction Raw material Currently carbon cost ~ 13 /kg Not enough cost decrease Next steps : Working on the carbon fiber value chain to reduce useless steps 2020: OakRidge US National lab: 11 /kg 2023: FORCE : 8 /kg Carbon fiber cost divided by 2 over a duration of 8 years 13 JEC World c

14 Material Working on material to reduce cycle time Raw material Fast cure : Application in 2012 on serial life production case Initial cycle time Open press 2 00 Closed press Open press 6 00 Preform introduction 2 00 Mold closing 0 35 Closed mold Mold opening 0 35 Demolding 3 30 Shaper 0 30 Mold cleaning 2 00 Deburring 1 30 Weighing 0 30 Next preform preparation 3 30 Operator is waiting Fast cure cycle time Open press 2 00 Closed press 6 40 Open press 6 00 Time cycle / 2 Preform introduction 2 00 Mold closing 0 35 Closed mold 5 30 Mold opening 0 35 Demolding 3 30 Shaper 0 30 Mold cleaning 2 00 Deburring 1 30 Weighing 0 30 Next preform preparation 3 30 Operator is waiting 0 40 Potential to reduce even more but bottleneck : Surrounding operations Looking for next step 14 JEC World c

15 1 Faurecia Composite Technologies 2 Where do composites stand? 3 Acting on the Composite value chain Raw material Process Product Assembly Engineering 4 Conclusion 15

16 Process Reconsider both Material and Process Process New processes require to reduce semi-finished products. Benefits : Cost Geometry freedom Benefit from specific material property + flexibility Reactive Thermoplastic RTM Example In mold combination of dry fabrics and resin Integration of ribs Very high fluidity of caprolactam grants a better fiber impregnation Opportunity to increase fiber content ratio Reduce cycle time and clamping force Net-shape part production 16 JEC World c

17 Process Reconsider both Material and Process Process Key points: Integration of Fast form benefits Program ends : Dec 2017 Part to part target : 120sec Currently 157sec Fully automated process compliant with automotive mass market 17

18 1 Faurecia Composite Technologies 2 Where do composites stand? 3 Acting on the Composite value chain Raw material Process Product Assembly Engineering 4 Conclusion 18

19 Details Product Reduce cost and weight Move from black metal approach Function integration Shape freedom, tooling, assembly Speak at higher level in the development V-cycle Benefit of tailored design opportunities Put the right material at the right place Playing on Stacking sequence Glass / carbon or Hybrid metal mix Reinforcement volume ratio Overmolding Global spec. Function integration Architecture. Detailed spec. Time Detailed design Unitary test Product Integration test Validation test Benefit of highly adaptability of composites 19

20 1 Faurecia Composite Technologies 2 Where do composites stand? 3 Acting on the Composite value chain Raw material Process Product Assembly Engineering 4 Conclusion 20

21 Assembly Assembly Hybrid assembly Magnetic Pulse Spot welding Metallic Insert Composite Plate with Metallic Insert inside Coil Flyer Sheet Air gap with Hump Welding Steel Steel + Zinc: e 0,49µm Zinc: e 3,8 µm Alu + Zinc: e 3,5 µm Alu Benefits Welding analysis : perfect adhesion Metal insert ok for manufacturing (easier than ) Compatible with multi-material welding with BIW : steel, steel+zinc, aluminum Assembly process compliant with existing OEM assembly line 21

22 1 Faurecia Composite Technologies 2 Where do composites stand? 3 Acting on the Composite value chain Raw material Process Product Assembly Engineering 4 Conclusion 22

23 If not OK Engineering Enhanced Engineering scheme Engineering Important evaluation times No process product coupling - Negligible computation time increase by process and costing consideration - Mechanical simulation and costing predictions enhanced with Process Estimator outcome 23

24 Engineering Example of part optimization 7 zones with independent material lay-up UD and chopped fiber material (carbon & glass) Zones defined using topology optimizations with an isotropic material Main process parameter is the injection time (fixed curing time) Optimization results: Standard approach Engineering Enhanced approach 100 % & Part mass: + 5 % Part filling time: - 96 % Total cycle time: - 29 % Total part cost: - 10 % 100 % & Important part cost reduction with process consideration 24

25 Stress (Mpa) Engineering Engineering SIMULATION applied to COMPOSITES Raw Materials And Sub-Process Manufacturing PROCESS PRODUCT Design Assemblies Material Laws Optimization Optimization Optimization SB63G1-T1.5 HSR 45-degree angle Pre-forming / wrapping Composite / Composite or Composite / Metal 150 HSR Tensile 45 23C s HSR Tensile 45 23C - 2 s-1 HSR Tensile 45 23C - 28 s-1 HSR Tensile 45 23C - 50 s-1 50 HSR Tensile 45 23C s Strain (%) Crash / Energy absorption : Thermoforming 25

26 Engineering Product & Process link Engineering Process simulation results, Input for product simulation Thermoforming simulation Product simulation without process consideration Product simulation with process consideration Trial Trial Mandatory to consider product-process dependency for complex parts 26

27 1 Faurecia Composite Technologies 2 Where do composites stand? 3 Acting on the Composite value chain 4 Conclusion 27 JEC World c

28 Conclusion Not one single value for target price per kg saved Composite deployment in Automotive mass market is not established. Carbon has the highest potential for improvement Mandatory check points : Important cost reduction and development of efficient engineering tools To act on multiple levers in the composite value chain To work jointly with OEM s : to speak at higher level than part spec 28 JEC World c

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