GF Automotive AG Carbon Fiber: A thread or opportunity for Lightweight Castings
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1 AG Carbon Fiber: A thread or opportunity for Lightweight Castings Klaus Decking
2 Georg Fischer Corporation More than 210 years of history, founded in 1802 Three core businesses, Piping Systems, Machining Solutions and Automotive 124 companies around the globe Sales of CHF 3.8 billion in employees 2
3 Our diversified profile Three times premium expertise and service to match our customers needs: GF Piping Systems GF Automotive GF Machining Solutions 39% CHF million 37% CHF million 24% CHF 905 million Total sales in 2014: CHF million 3
4 Production of lightweight cast components and systems Made out of ductile iron, aluminum and magnesium in sand casting and high pressure die casting For the global automotive industry and other industrial applications million (CHF) sales employees 10 companies worldwide Figures for
5 Casting orcarboncomposites? Iron Carbon Aluminum Herstellung Magnesium Recycling Repair Recycling Lower Energy Consumption Material Cycle Costs Corrosion Resistance Repair Lighter Production Resistance 5
6 Material Comparison Tensile Strength Rm (N/mm 2 ) 0.2%-Yield Stress Rp 0,2 (N/mm 2) Elongation (%) GJS GJS SiboDur Aluminum Magnesium Carbon Fiber Min Min Min Min Min Young s Modulus (kn/mm 2 ) Density (g/cm 3 )
7 Lightweighting Potential Weight Reduction Source University of Cambridge 7
8 Production Chain of Carbon Fiber and Magnesium Carbon Fiber Magnesium 8
9 Manufacturing Climate Balance Sheet CO 2 Emissions Due to pidgeon process Source University of Cambridge 9
10 Manufacturing Energy Consumption Energy Energy Consumption Consumption Due to pidgeon process Source University of Cambridge 10
11 Emission over Life-Cycle Change of Perspective: Break-Even Break Even: 0 km High Strength Steel km Aluminum km Magnesium km Carbon Fibre Source: VW, University of Cambridge 11
12 Availability Magnesium: 8th abundant element in earth s crust Carbon fiber: Uses polyacrylonitrile 12
13 Recycling Metals Carbon Fiber Fully recyclable Used in new alloys Used as a mixture in new alloys Recyclable? At least downcycling or scrap 13
14 Repair Job Metal Repair Carbon Fiber Repair 14
15 Cost Comparison Costs per Part (in % of Steel) Steel Aluminum Magnesium Carbon Today Up to 3 times higher costs for carbon fibre Tomorrow With new precursors and technological progress improving production processes, a decrease of almost 30% in the global cost of composites is expected between now and 2020 Source: McKinsey&Company, Magnesium own Research University of Cambridge 15
16 Carbon Fiber vs. Aluminum 100% Carbon? Source: BMW AG 16
17 Substitution of Sheet Metal Constructions Weight Reduction Casted aluminum compared to steel sheet assembly out of 10 parts up to 45% less weight 17
18 Carbon Fiber vs. Magnesium Carbon Fiber Magnesium Source BASF - 30% Weight Reduction compared to conventional Steel-based Designs - 30% Weight Reduction compared to conventional Steel-based Designs 18
19 Substitution of Sheet Metal Constructions Weight Reduction Seat frame in casted Magnesium up to 30% less weight than metal sheet assembly 19
20 High Design Freedom for Castings Front Steering Knuckle Carbon - 40% Iron - 35% 20
21 Bionic Design Weight reduction Iron steering knuckle up to 35% less weight through bionic design 21
22 Material Strengths and Weaknesses Iron / Steel Aluminum Magnesium Carbon Strength ++ + o ++ Costs ++ + o -- Energy Consumption + o - - Weight Reduction Repair Recycling ++ + o -- 22
23 Design 23
24 Bionic Design Start Principle Topological Optimization CAD (Quelle: Prof. Dr. Claus Mattheck) 24
25 Bionic Design Before GJS 700 7,2 kg After SiboDur 700 6,3 kg -12,5 % 25
26 Substitution of Aluminum through Magnesium in Powertrain Applications Weight reduction Front cover in casted Magnesium up to 45% less weight than aluminum 26
27 Process Know how to cast Material Design Prozess Validierung 27
28 Substitution of System Parts Weight Reduction Crossmember, completely casted in iron has 17% less weight than combined assembly out of steel sheet and iron 28
29 Substitution of Sheet Metal Constructions Weight Reduction Inno Door Frame in casted Aluminum up to 40% less weight than metal sheet assembly 29
30 Casting Advantages Design Freedom + Variation of Wall Thicknesses 100% Recyclable Functional Integration Weight Reduction Potential Cost Efficiency Mass Production for complex Parts 30
31 Joining of Parts in the Body Structure Screwing Compound casting Electro magnetic forming Clinching Adhesives Delta-spot welding 31
32 Lightweight Design by Multi-Material Mix: Metal / Plastics Plastic Housing Casting 32
33 Passion for your Lighter Future 33
34 Contact Klaus Decking Head of Marketing, Communication & Services Business Development New Markets Phone Mobile Fax GF Automotive Georg Fischer Automotive AG Amsler-Laffon-Strasse Schaffhausen Switzerland 34
35 Disclaimer This document is for presentation purposes only and should not be construed as an offer, invitation or solicitation to subscribe for, purchase or sell any investment. Neither it nor anything it contains shall form the basis of any contract whatsoever. The management of Georg Fischer does not accept any liability whatsoever with respect to the use of this presentation. Opinions expressed herein reflect the current judgement of the management of Georg Fischer. The presentation contains forward-looking statements that involve risks and uncertainties. The actual results of Georg Fischer may differ materially from those anticipated in these forward-looking statements and forecasts as a result of a number of factors. 35
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