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Carbon fibre SMC halves weight of automotive parts
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03/07/2003
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Carbon fibre SMC halves weight of automotive parts
Sample panel in carbon SMC.
EUROPEAN resin producer DSM Composite Resins has developed a carbon fibre sheet moulding compound (SMC) for use in making low weight semistructural and structural automotive components.
Parts made with the carbon fibre SMC can weigh as much as 55% less than those made of traditional SMC, claims the company. The material is designed for applications that do not require the high quality Class A surface of exterior panels, and is said to have good flow properties with fibres distributed evenly throughout the moulding. Its curing time and closing speed are comparable to those for standard SMC. Moulded carbon SMC with a 50% fibre volume by weight has a specific weight of 1.5, and its mechanical properties are significantly better than standard SMC, says DSM.
Weight savings made by making components from carbon fibre SMC also lead to weight reductions in the connecting and supporting components and fixings, says DSM. The improved mechanical properties also allow less material to be used to achieve the same stiffness. Wall thicknesses are reduced by up to 38%, claims the company, with total weight savings reaching 55% over traditional SMC. DSM Composite Resins; tel: +49-621-60-42506; fax: +49621-60-92691; website: www. dsmcompositeresins.com.
Alloys make processing easier FRENCH company Rhodia Engineering Plastics has launched a family of polyamide/acrylonitrile butadiene styrene (PA/ABS) alloys including a glass reinforced grade for extra stiffness. The Technly® Alloy range is targeting automotive applications such as instrument panels, fascias, air-vent and defroster grilles and door assemblies, motorcycle fairings and scooter exteriors. Automotive manufacturer GM/ Daewoo is already planning to use the materials for a high performance centre fascia in its Kalo sports utility vehicle (SUV). Other potential applications include consumer and sporting goods, electrical components and appliance housings, says Rhodia. The new grades are claimed to offer an excellent balance of stiffness and impact strength, high quality appearance, lower specific gravity and better processing than competing products, and
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the opportunity to reduce systems costs. Because Technyl Alloy has a lower density than similar products, part weights are reduced, says Rhodia. It adds that components are heat resistant up to 200°C and offer more design flexibility than other products, while the improved ductility makes the grades particularly suited to automotive interior door panels. Noise damping is also said to be improved. The grades are designed to resist stress cracking and the use of PA provides added protection against detergents. Properties that Rodia says make Technyl Alloy ideal for automotive interior components include scratch resistance, durability, matt surface aspect and colour stability. With a high fluidity and wide processing window, the grades are easy to fabricate, says Rhodia, especially in parts with long flow lengths or
July/August 2003
sharp changes in thickness. Because of this, moulders can use a lower injection clamping force and temperature, which reduces tooling costs. According to the company, shear stress is low so warpage and post-mould shrinkage in the final part is lower than for typical PA applications. Rhodia Engineering Plastics; website: www.rhodia.com.
PA/ABS alloys will be used for the centre fascia of the Daewoo Kalo.
SP launches blade prepreg A GLASS fibre prepreg for use in making wind turbine blades was unveiled by UK-based company SP at the European Wind Energy Conference in Spain in June. WE90 is a high flow, epoxy prepreg which is said to be ideal for the thick sections found in turbine blades. It can be cured at temperatures as low as 85°C or used in the rapid manufacture of components through a 45 minute cure at 120°C. According to SP, the prepreg offers excellent laminate quality and low bleed content, with high performance tacking capabilities and a shelf life of 60 days at room temperature. WE90 is currently available in unidirectional, biaxial and triaxial E-glass fibre. SP; tel: +44-1983-828322; website: www.spsystems.com.
Thermoplastic composite for auto parts QUADRANT Plastic Composites (QPC) has begun producing SymaLITE composite, a combination of polypropylene and glass fibres, at its site in Lotte, Germany. QPS, which claims to be the world’s leading manufacturer of glass mat thermoplastic (GMT), says Symalite components can be fabricated using a compression moulding process, and that the density of the parts can be varied. Symalite can be used in automotive applications such as head linings, sun shields and shelves, underbody components, and parts of varying density and thickness. QPC; tel: +41-62-8858-312; website: www.quadrantcomposites.com.
03/07/2003
12:13
Page 16
Carbon fibre SMC halves weight of automotive parts
Sample panel in carbon SMC.
EUROPEAN resin producer DSM Composite Resins has developed a carbon fibre sheet moulding compound (SMC) for use in making low weight semistructural and structural automotive components.
Parts made with the carbon fibre SMC can weigh as much as 55% less than those made of traditional SMC, claims the company. The material is designed for applications that do not require the high quality Class A surface of exterior panels, and is said to have good flow properties with fibres distributed evenly throughout the moulding. Its curing time and closing speed are comparable to those for standard SMC. Moulded carbon SMC with a 50% fibre volume by weight has a specific weight of 1.5, and its mechanical properties are significantly better than standard SMC, says DSM.
Weight savings made by making components from carbon fibre SMC also lead to weight reductions in the connecting and supporting components and fixings, says DSM. The improved mechanical properties also allow less material to be used to achieve the same stiffness. Wall thicknesses are reduced by up to 38%, claims the company, with total weight savings reaching 55% over traditional SMC. DSM Composite Resins; tel: +49-621-60-42506; fax: +49621-60-92691; website: www. dsmcompositeresins.com.
Alloys make processing easier FRENCH company Rhodia Engineering Plastics has launched a family of polyamide/acrylonitrile butadiene styrene (PA/ABS) alloys including a glass reinforced grade for extra stiffness. The Technly® Alloy range is targeting automotive applications such as instrument panels, fascias, air-vent and defroster grilles and door assemblies, motorcycle fairings and scooter exteriors. Automotive manufacturer GM/ Daewoo is already planning to use the materials for a high performance centre fascia in its Kalo sports utility vehicle (SUV). Other potential applications include consumer and sporting goods, electrical components and appliance housings, says Rhodia. The new grades are claimed to offer an excellent balance of stiffness and impact strength, high quality appearance, lower specific gravity and better processing than competing products, and
16
REINFORCEDplastics
the opportunity to reduce systems costs. Because Technyl Alloy has a lower density than similar products, part weights are reduced, says Rhodia. It adds that components are heat resistant up to 200°C and offer more design flexibility than other products, while the improved ductility makes the grades particularly suited to automotive interior door panels. Noise damping is also said to be improved. The grades are designed to resist stress cracking and the use of PA provides added protection against detergents. Properties that Rodia says make Technyl Alloy ideal for automotive interior components include scratch resistance, durability, matt surface aspect and colour stability. With a high fluidity and wide processing window, the grades are easy to fabricate, says Rhodia, especially in parts with long flow lengths or
July/August 2003
sharp changes in thickness. Because of this, moulders can use a lower injection clamping force and temperature, which reduces tooling costs. According to the company, shear stress is low so warpage and post-mould shrinkage in the final part is lower than for typical PA applications. Rhodia Engineering Plastics; website: www.rhodia.com.
PA/ABS alloys will be used for the centre fascia of the Daewoo Kalo.
SP launches blade prepreg A GLASS fibre prepreg for use in making wind turbine blades was unveiled by UK-based company SP at the European Wind Energy Conference in Spain in June. WE90 is a high flow, epoxy prepreg which is said to be ideal for the thick sections found in turbine blades. It can be cured at temperatures as low as 85°C or used in the rapid manufacture of components through a 45 minute cure at 120°C. According to SP, the prepreg offers excellent laminate quality and low bleed content, with high performance tacking capabilities and a shelf life of 60 days at room temperature. WE90 is currently available in unidirectional, biaxial and triaxial E-glass fibre. SP; tel: +44-1983-828322; website: www.spsystems.com.
Thermoplastic composite for auto parts QUADRANT Plastic Composites (QPC) has begun producing SymaLITE composite, a combination of polypropylene and glass fibres, at its site in Lotte, Germany. QPS, which claims to be the world’s leading manufacturer of glass mat thermoplastic (GMT), says Symalite components can be fabricated using a compression moulding process, and that the density of the parts can be varied. Symalite can be used in automotive applications such as head linings, sun shields and shelves, underbody components, and parts of varying density and thickness. QPC; tel: +41-62-8858-312; website: www.quadrantcomposites.com.