LIGHTER VEHICLES STARTS WITH SIKA

Transcription

1 BETTER VEHICLES ǀ START WITH SIKA LIGHTER ǀ STRONGER ǀ SAFER ǀ QUIETER ǀ GREENER LIGHTER VEHICLES STARTS WITH SIKA DR. MOREL NICOLAS GLOBAL PRODUCT AND MARKETING MANAGER SIKA AUTOMOTIVE AG - SWITZERLAND

2 AGENDA SIKA AUTOMOTIVE: Who we are and what we do Building Trust LIGHTER VEHICLE START WITH SIKA: Saving up to 150 kg with Sika s lightweight solusons MIXED MATERIAL BONDING: Sikaflex Ultra High Modulus v Adhesion performance v Mechanical properses v Process ability v Durability

3 WHAT WE DO BUILDING TRUST Sika is a specialty chemicals company with a leading posi1on in the development and producson of systems and products for bonding, sealing, damping, reinforcing, and protec1ng in the building sector and the motor vehicle industry. SIKA AT A GLANCE 17,000+ TEAM MEMBERS 90+ COUNTRIES 170+ FACTORIES WORLDWIDE 9 NEW FACTORIES IN NEW PATENTS IN ACQUISITIONS IN BN NET SALES (CHF) IN 2015 WE ARE THERE Our products might not always be visible but the results they achieve are clear to see. 3

4 TARGET MARKETS CONCRETE WATERPROOFING ROOFING FLOORING SEALING AND BONDING REFURBISHMENT INDUSTRY AND AUTOMOTIVE 4

5 SIKA AUTOMOTIVE TECHNOLOGY SEGMENTS BIW STRUCTURAL INSERTS ACOUSTIC SYSTEMS BODY SHOP ADHESIVES TRIM & ASSEMBLY ADHESIVES INTERIOR/EXTERIOR ADHESIVES PAINTSHOP (LaSn America) 5

6 SIKA AUTOMOTIVE GLOBAL REACH, LOCAL PRESENCE Our products proudly serve ALL major global and local OEM s, OES and Ser component suppliers in their regions 6

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8 ASSEMBLY LINE ADHESIVES & SEALANTS MIXED MATERIAL BONDING Aluminum Roof Bonding with 1C- PUR Sikaflex Ultra High Modulus 8

9 MIXED MATERIAL BONDING SIKAFLEX - ULTRA HIGH MODULUS (UHM) InnovaSve 1C- PUR system Sika Booster system To enlarge use of mixed materials in car body construcson High elasscity Brings excellent crash resistance as well as accommodates Δα High modulus Provided ssffness to the bonded parts Allows fast handling of the bonded parts i- cure technology Allows very fast curing without blistering InnovaSve addisves Provides excellent and durable adhesion on various substrates 9

10 MULTI- MATERIAL BONDING IN THE ASSEMBLY LINE CHALLENGES Challenging substrates (Plas1c/metal/e- coat/paint/ oil ) High stress level on substrates Need for innova1ve adhesion promotors Adhesion Performance Mechanical Proper1es Need for crash resistance of body structure Need for car body s1ffening Accommoda1on of Δα Durability Manufacturing Process Need for new tes1ng methods (corrosion/long term stability ) CAE to support the understanding MMJ behavior Need for innova1ve joining methods (fast/cold curing, high green strength ) Bonding solu1ons with good performance/cost ra1o 10

11 SIKAFLEX UHM + BOOSTER ADHESION AND PRE- TREATMENTS Understanding that adhesion is a substrate and process specific property and must be tested on original substrates. If adhesion problems on a specific substrate should occur an appropriate pretreatment is required. Preliminary results with Sika pretreatments for paints, metals and plasscs are available Solvent and water based acsvators and primers are available from the shelf Development of LOT primer for plasscs ongoing. 11

12 MULTI- MATERIAL BONDING IN THE ASSEMBLY LINE CHALLENGES Challenging substrates (Plas1c/metal/e- coat/paint/ oil ) High stress level on substrates Need for innova1ve adhesion promotors Adhesion Performance Mechanical Proper1es Need for crash resistance of body structure Need for car body s1ffening Accommoda1on of Δα Durability Manufacturing Process Need for new tes1ng methods (corrosion/long term stability ) CAE to support the understanding MMJ behavior Need for innova1ve joining methods (fast/cold curing, high green strength ) Bonding solu1ons with good performance/cost ra1o 12

13 MODULAR BONDING IN THE ASSEMBLY LINE CHALLENGE: THERMAL EXPANSION DELTA- ALPHA Design of Bonding Geometry: General rules for elassc adhesive joints (Sika Handbook for ElasSc Bonding): 1. stasc stress < 3% of lap shear strength 2. thermal movement (shear) max. 50% of bonding thickness Example: PC/steel: 1. thermal expansion = 5.6mm ( T = 60 K) 2. if part is free to move at both ends: half for each bonding end = 2.8mm 3. movement must be < 50% of bonding thickness ð > 5.6mm ð Bonding geometry needs to be calculated case by case Minimizing sta1c loads: Curing of the adhesive in the middle of the service temperature range (approx. 20 C) 80 C 20 C - 40 C ð Full curing in- house required (= accelerated curing) 13

14 MODULUS VS. TEMPERATURE - DMTA ANALYSIS CHALLENGE: CONSTANT MODULUS (T) 1.0E+04 Modul M* 1.2 Modul M* [MPa] 1.0E E E E E- 01 T g T g U1lity range Sikaflex UHM Standard 2C PUR Tangens Delta 1.0E- 02 Tangens Delta E Temperatur [ C] 0 Modul M* UHM Modul M* 2K- PUR M*(- 40 C) Tangens Delta UHM Tangens Delta 2K- PUR M*(80 C) M*(- 40 C)/M*(80 C) Sikaflex - UHM Approx. 5 Standard 2C PUR Approx

15 SUMMARY OF MECHANICAL PROPERTIES CHALLENGE: STIFFENING & CRASH RESISTANCE Proper1es Tensile strength ElongaSon E- modulus ( %) G- Modulus Glass transison (Tg) Sikaflex UHM (typical range) 8-12 MPa % MPa 5-15 MPa - 55 C ð UHM Bonding: high s1ffness provided by high strength 15

16 CRASH PERFORMANCE CHALLENGE: STIFFENING & CRASH RESISTANCE High crash resistance due to high strength AND high elongason Structural bonding Material failure Elastic bonding Cohesive failure 6000 Force [N] W elastic = 2 x W rigid Displacement [mm] 16

17 SIKAFLEX UHM ADHESIVE VS SPOT WELDING CHALLENGE: STIFFENING & CRASH RESISTANCE Length [mm] Original length Spot welding Sikaflex UHM Spot welding + structural adhesive ð UHM Bonding: Crash performance beier than spot welding! 17

18 MULTI- MATERIAL BONDING IN THE ASSEMBLY LINE CHALLENGES Challenging substrates (Plas1c/metal/e- coat/paint/ oil ) High stress level on substrates Need for innova1ve adhesion promotors Adhesion Performance Mechanical Proper1es Need for crash resistance of body structure Need for car body s1ffening Accommoda1on of Δα Durability Manufacturing Process Need for new tes1ng methods (corrosion/long term stability ) CAE to support the understanding MMJ behavior Need for innova1ve joining methods (fast/cold curing, high green strength ) Bonding solu1ons with good performance/cost ra1o 18

19 PROCESS PROPERTIES - APPLICATION PROPERTIES CHALLENGE: FAST HANDLING 1C Polyurethane with ultra- high modulus binder Excellent applicason properses Curing with humidity AcceleraSon with Sika Booster possible Powered by Sika s patented i- cure technology: bubble free curing 19

20 PROCESS PROPERTIES - APPLICATION PROPERTIES CHALLENGE: FAST HANDLING Standard 1C PUR: Humidity Diffusion into Adhesive Sika Booster: Admixing of approx. 2% of a accelerator curing paste 1C- PUR 1C- PUR Curing from Surface to the Center Booster Accelerates curing Independant of environmental climate No change of mechanical properses High mixing tolerance 20

21 MULTI- MATERIAL BONDING IN THE ASSEMBLY LINE CHALLENGES Challenging substrates (Plas1c/metal/e- coat/paint/ oil ) High stress level on substrates Need for innova1ve adhesion promotors Adhesion Performance Mechanical Proper1es Need for crash resistance of body structure Need for car body s1ffening Accommoda1on of Δα Durability Manufacturing Process Need for new tes1ng methods (corrosion/long term stability ) CAE to support the understanding MMJ behavior Need for innova1ve joining methods (fast/cold curing, high green strength ) Bonding solu1ons with good performance/cost ra1o 21

22 SIKAFLEX UHM + BOOSTER STABILITY OF CURED ADHESIVE DURING LIFE- CYCLE Understanding how aging and exposison to heat, humidity and to chemicals influence the bonding system stability during life cycle T [ C] + 90 Ageing Cycle Adhesion and mechanical properses are stable. Exposure to heat, cataplasm and water immersion is tested up to 2160h. Results available Further applicason specific stability tests may be required To be discussed and defined - 30 t [h] 22

23 SIKAFLEX ULTRA HIGH MODULUS TECHNOLOGY EXISTING APPLICATIONS Life Module- to- Chassis Bonding: Sikaflex - UHM technology Ultra high modulus accelerated 1C- PUR Adhesive for semi- structural bonding of mixed material CFRP Life module / Aluminum chassis Roof Module Bonding: Sikaflex - UHM technology Ultra high modulus 1C- PUR Adhesive for semi- structural bonding of mixed material E- coated Aluminum Roof / Painted Steel Body CUSTOMER BENEFITS q Durable Assembly of mixed material (large size parts) q SimplificaSon of Body ConstrucSon Process (Cold Body Shop) 23

24 KG SAVED EVERY YEAR BY BONDING MIXED MATERIAL WITH SIKAFLEX - UHM