Advanced GMT Applications in the Automotive Industry Richard Broo Quadrant Plastic Composites, Inc. Harri Dittmar Quadrant Plastic Composites AG SPE Automotive Composites Conference Advanced GMT Applications Content:
Download ReportTranscript Advanced GMT Applications in the Automotive Industry Richard Broo Quadrant Plastic Composites, Inc. Harri Dittmar Quadrant Plastic Composites AG SPE Automotive Composites Conference Advanced GMT Applications Content:
Slide 1
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 2
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 3
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 4
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 5
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 6
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 7
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 8
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 9
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 10
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 11
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 12
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 13
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 14
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 15
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 16
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 17
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 18
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 19
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 20
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 21
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 22
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 23
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 24
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 25
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 26
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 27
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 28
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 29
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 30
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 31
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 32
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 33
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 34
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 35
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 2
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 3
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 4
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 5
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 6
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 7
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 8
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 9
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 10
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 11
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 12
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 13
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 14
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 15
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 16
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 17
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 18
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 19
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 20
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 21
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 22
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 23
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 24
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 25
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 26
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 27
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 28
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 29
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 30
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 31
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 32
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 33
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 34
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years
Slide 35
Advanced GMT Applications
in the Automotive Industry
Richard Broo
Quadrant Plastic Composites, Inc.
Harri Dittmar
Quadrant Plastic Composites AG
SPE Automotive Composites Conference
Advanced GMT Applications
Content:
Cost Saving in the Automotive Industry
Benefits of Advanced GMT Applications (GMT and GMTex)
Definition and Material Basics of GMTex
Product and Process Information
Impact Performance
Current Applications
Future Developments
Summary
Advanced GMT Applications
Cost Saving - which costs are we talking about?
Material costs: not useful, since the amount of material
needed for a certain part is different between metals and
composites
Part costs: misleading, since plastic and composite parts
usually have a higher degree of functionality compared to
metal parts (even reduced number of parts)
Costs for defined functions: also not a good measure,
since assembly costs are not taken into account
Proposal: to compare different materials for a certain
application, costs for the final assembled part having the
same number of functions like the metal part or group of
parts are the best measure (examples: frontend and roof
module)
Advanced GMT Applications
Cost Savings for OEM`s with Advanced GMT Applications:
Weight saving (improved fuel economy)
High degree of function integration (less parts, reduced
logistics)
Reduced assemly effort (belt length) and costs
High productivity of part production (cycle times: 20s @
2 mm wall thickness)
Low tooling costs compared to steel stamping tools
(better efficiency for cars with low production numbers:
< 100 000 cars per year)
Advanced GMT Applications
Benefits of Advanced GMT Applications:
Cost and weight savings like for plastics in general but
use of parts out of advanced GMT possible:
• at elevated temperatures
• under creep loads
• under fatigue loads
• impact conditions (energy management)
Advanced GMT Applications
Material Basics: Definition of GMTex
GMTex is a combination of classical mat-based GMT with
one or more layers of endless fibers as woven fabrics or
non-crimped stitched products out of various fibers
Twintex
Glass fabric
PET special weave
Glass-Aramide
non-crimped
Advanced GMT Applications
Material Basics: Single Ply Design of GMTex
The number and orientation of endless reinforcing fibers in
a single textile layer of GMTex can be tailored according to
the requirements of the specific application:
0°
E-Modulus of PP-GM40
0°
15000
15000
315°
270°
45°
0
225°
315°
90°
135°
180°
270°
45°
0
225°
135°
180°
E-Modulus of GMTex
90°
Advanced GMT Applications
Material Basics: Laminate Design of GMTex
Tailoring of properties by variation of type and number of
reinforcing textile layers:
Tensile stiffness (MPa)
50000
40000
30000
20000
10000
0
GMT
40% GF
UD-GMT
40% GF
UD-GMTex
60% GF
UD-GMCTex
30% GF-20%
CF
Advanced GMT Applications
Advanced GMT
GMTex
Production of GMTex:
Glass mats
Extruded PP-films
Middle-layer
Textile
reinforcements
Surface-layer
Double Belt Press
Advanced GMT Applications
Molding of GMTex:
GMTex blanks
Hot air oven
Position of fabrics
in the molded part
Preheated blank
Preheated blanks in the mold
Molded part
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Excellent crash resistance and stiffness
Integrated hip protection
Multiple fixation devices, snap fits for wiring
Door and window opening system guidance
High productivity ( > 1000 parts/day)
Recyclability
Tier 1: Lames
Molder: Rangerplast Italy
Part weight: 1,5 kg
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Tested materials:
PP-GM40 (serial material), PP-GM30
DLFT 40% glass content
LFT pellets (Stamax) 40% glass content
GMTex and PP-GM30
Blank layout for GMTex:
GMTex stripes Middle-Layer
GMTex Toplayer 1/1, +/-45°
(only for hip protection tests)
GMT 30%
Advanced GMT Applications
Impact Performance - Lancia Y Door Module
Crashtests carried out in cooperation with Rangerplast Italy to
evaluate capabilities of GMT and GMTex in comparison to other
materials
Side impact test (pole test) with
clamped parts, fixations can
rotate
Hip protection pad impact, flat
impactor on barrier behind
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
D-LFT 40% @400J - Absorption 250 J
Crash-Video
Crash-Video
GMT 40% @ 400J - Max. Absorption 800 J
Crash-Video
GMTex ML @1000J - Absorption 1000 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at side impact test
STAMAX 40% @400J - Absorption 120 J
GMT 40% @ 400J - Max. Absorption 800 J
D-LFT 40% @400J - Absorption 250 J
GMTex ML @1000J - Absorption 1000 J
Advanced GMT Applications
Results of side impact tests:
Side impact energy absorption
1200
1000
J
800
600
Side impact
400
200
0
Stamax 40% D-LFT 40%
GMT 30%
GMT 40%
GMTex ML
GMTex performance is limited by weak fixation points !
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
Crash-Video
GMT 40% @ 1200 J - max. absorption 900 J
Crash-Video
D-LFT 40% @ 900 J - max. absorption 500 J
Crash-Video
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Crash-Video
Advanced GMT Applications
Comparison of energy absorption and failure behavior at hip pad impact test
STAMAX 40% @ 900 J - max. absorption 450 J
GMT 40% @ 1200 J - max. absorption 900 J
D-LFT 40% @ 900 J - max. absorption 500 J
GMTex TL +/-45° @ 1440 J - max. absorption 1300 J
Advanced GMT Applications
Results of hip pad impact tests:
Hip pad impact energy absorption
1400
1200
1000
J
800
Hip pad impact
600
400
200
0
Stamax
40%
D-LFT 40%
GMT 30%
Brittle failure !
GMT 40%
GMTex ML
Advanced GMT Applications
Current Advanced GMT Applications
Structural Instrument Panels
Seat Structures
Battery Boxes
Bad Road Engine Noise Shields
Spare Wheel Wells
Hatchback Doors
Bumper Beams
Rear Axle Supports
Advanced GMT Applications
Current Applications: Structural Instrument Panel - Ford C1
Platform (Mazda 3, Ford C-Max, Volvo S40/V50)
Excellent crash resistance and
stiffness
In-molded cross-car beam
Integration of functions +
fixations : air ducting, airbag
and glovebox support,
knee bolster, air conditioning
LL / RL utilisation same part
Weight reduction (2 to 3 kg per
component)
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Part weight: 3,2 - 3,5 kg
Tier 1: Faurecia
Molders:
Nishikawa (Mazda)
Faurecia (Ford)
FPK (Volvo)
Advanced GMT Applications
Current Applications: Front Seat Base and Seat Back
(Bentley Continental GT)
Excellent crash resistance and
stiffness
Cost savings compared to steel and
aluminum tooling due to low car
production numbers
Weight reduction compared to steel
High productivity ( > 1000 parts/day)
Recyclability
Molder: Polynorm UK
Part weights: 1,1 / 1,3 kg
Advanced GMT Applications
Current Applications: Battery Box (Porsche Cayenne and
VW Touareg)
Excellent crash resistance: battery with
a weight of 30 kg is dropped from 300
mm into the box - no damage
Weight reduction
High productivity ( > 1000 parts/day)
and low cost tooling
Recyclability
Part weight: 2,1 kg
Molder: Rangerplast Italy
Advanced GMT Applications
Current Applications: Bad Road ENS: Audi, BMW, DC, Rover
GMTex with polyester weave
gives extreme wear and
impact resistance
Engine Protection Shield Audi C5
Advanced GMT Applications
Current Applications: Spare Wheel Wells
(DaimlerChrysler C-/E-/S-Class, VW, Audi)
Excellent crash resistance,
stiffness and fatigue strength
Bonded into BIW with PUR
adhesive used for glazing
Weight reduction
Better acoustics compared to
steel
No additional corrosion
protection
High productivity ( > 1000
parts/day) and low cost tooling
Recyclability
Molder: Aksys
Part weight (C-Class): 4,2 kg
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Stagea)
- Weight saving vs steel
- Improved crash behavior due to GMTex
- Hinges attached to steel profile
- Narrow profile gives better rear visibility
- Thin ribs due to improved GMT flow
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Murano)
Advanced GMT Applications
Current Applications: Hatchback Doors (Nissan Infinity FX45)
Designs of Murano
and Infinity hatchback
doors in steel not feasible
Advanced GMT Applications
Current Applications: Bumper Beams (Peugeot 407)
407 with integrated brackets
and crash absorbers for
Allianz / Daner ranking
History 2: 806 with integrated brackets
History 1: 805 with additional metal brackets
Advanced GMT Applications
Current Applications: Rear Axle Support
(All Volvo AWD Models)
Top
Side
Bottom
- Weight reduction: 2 kg GMTex vs. 3 kg aluminum
- Improved fatigue: 3 x the lifetime of aluminum
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations can be disclosed):
Motor Supports
Lower Leg Beams for Pedestrian Protection
Rear Seat Backs with integrated seating belt
Advanced GMT Applications
Future Developments: Motor Supports (Volvo Test Fleet, 20
Taxis at Göteborg)
Weight reduction: 31% (14 vs. 20,5 kg) with
first prototypes using only random GMT the use of GMTex will reduce the weight further
Longterm creep and fatigue tests performed before driving tests
Advanced GMT Applications
Future Developments: Pedestrian Protection Beam
(VW: various models)
- Cost & weight savings vs. steel and foam
- Superior impact properties vs. LFT / IM / ICM
Advanced GMT Applications
Future Developments of Advanced GMT Applications
(Informations cannot be disclosed):
Structural Front Ends
Rear (Wall) Modules
Parts for a „3rd Crash Level“
Airbag Containers
Airbag Covers
Fire Walls
Floor Modules
Advanced GMT Applications
Summary:
Advanced GMT-applications using GMT and GMTex show
already their performance in existing cars
Cost and weight savings are the key benefits for the
automotive industry using these materials
Compared to materials like (D)LFT, IM and ICM these
materials show superior properties like stiffness, impact,
creep and fatigue
High flexibility of reinforcement fibers, type and number of
textile reinforcements gives efficient tailoring of properties
New and challenging applications are under development
and will be in the market in the coming years