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TRANSCRIPT
Composites:Applications & Trends in
Automotive Industry
Gokul Venkataraman.
Hyderabad – June 16th - 2012
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Agenda
• Owens Corning businesses at a glance
• A sneak peek into the India Auto industry
• Composites in Automotive Segment - Advantages & Trends…!
• Summarizing..!
3
Owens Corning businesses at a glance
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Owens Corning At A Glance
• Founded in 1938, is a leading global producer of residential
and commercial building materials, glass-fiber
reinforcements and engineered materials for composite
systems
• 2011 sales: $5.3 billion
• 15,000 employees in 28 countries
• FORTUNE 500 company for
58 consecutive years
• Residential Insulation
• Commercial & Industrial Insulation
• Residential Shingles
• Roofing Asphalts
• Composites
A Global
LeaderLeading North American
Market Positions
www.owenscorning.com
5A Global Glass Reinforcement Supplier
Owens Corning’s Global Composites
• 2011 sales: $1.9 billion vs. $5.3 billion for
global Owens Corning
• 7,600 employees worldwide
• Nearly 40 plants in 15 countries
• R&D centers in Granville (Ohio), Chambéry
(France), Ibaraki(Japan), Zele(Belgium),
Apeldoorn (Netherlands), Shanghai (China
-coming soon)
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Power / EnergyWind Energy, Power Plants, Refineries,
Energy Exploration & Transportation,
Other Renewable
TransportationLight Vehicles, Trucks, Other
Water DistributionPotable Water, Sewage, Storage &
Treatment
HousingRoofing, Sanitary, Construction & Other
Aerospace/DefenseAircraft, Military & Security
Composite End-Use Markets
ConsumerMarine, Sports & Leisure, Appliance &
Other
IndustrialFactories, Roads & Bridges,
Communications, Commercial Construction
& Other
www.composites.owenscorning.com
7www.ocvreinforcements.com/solutions/Standard_Reinforcements.asp
Our glass reinforcements are made in
various forms in order to make them
suitable for a variety of processes and
to provide desired thermo-mechanical
and electrical properties
Owens Corning Solutions
Single-End Roving,
Multi-End Roving (OC Hilight™ roving),
BMC/RTP Chopped Strands,
Chopped Strand Mat,
Continuous Filament Mat
Final Applications
Comprehensive Range of Reinforcements
for Each Market
Copyright © iP; Blanchard (FR)
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Owens Corning Solutions
www.ocvreinforcements.com/hp
High Performance Reinforcements –
Stronger, Stiffer, Lighter
Compared to standard E-glass, enabling
to achieve(*)
• Up to 50% higher strength with S-glass
• Up to 20% higher modulus with S-glass
• End-use parts have higher fatigue
properties
• Up to 80% better impact resistance
• Better aging and corrosion resistance
than E-CR/E-glass
• Better resistance at elevated
temperaturesFinal Applications
(*) Owens Corning testing
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Auto OE’s Wide Presence Across India..!
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Passenger Car sales are booming..!
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Growth continues in Other Vehicles..!
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Key Automotive Drivers:
Environment > Weight Out, Aerodynamics, Emissions Reduction,..
Occupant & Pedestrian Safety > Higher Performance Components
End of Life Vehicle Legislation > Recyclability…Design, Materials
Financial Performance Issues > Cost Out…Part Integration…Modular Designs
Mass Customization > Less Platforms, more Offers customized to
Customers
Owner Ship > Customer Satisfaction, Robustness, Insurance
Ratings
Paint Out (Cost & Environment) > Paintless Film Based Body Panels
Auto Industry Trends & Drivers
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Challenges in Automotive segment
• Energy Limitation
– Today, Oil Consumption is over 80 mio. barrels/day and still increasing...
– Oil & Natural gas reserves are limited.
– Substitution energies (biofuel, nuclear, hydraulic, solar, eolian, tidal, ...)
– Production & Technology limitations
– Storage & Transportation issues
• Environmental Concerns
– 16% of global made-made CO2 emissions
comes from Road Transport
– CO2 emission due to human activity are
participating to climate change (wide
agreement).
– Automobile represents an improvement of
life quality
– Sustain the benefits of vehicles
– Reduce environmental impact
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• Mahindra & Mahindra wants to build an SUV that weighs less than a
tonne…! The company saves 80-90 per vehicle for every kg of weight
loss..!*
• Maruti has saved Rs 147 crore by working on one-gram weight
reductions on components... all because customers want lighter cars
that drink less fuel and cause less pollution..!*
Simplified Borrowed Analogy on Weight Reduction * –
Equivalent of toning down a sumo wrestler to Salman Khan size..!*
* Source – The Economic Times – Oct 18th, 2011
Weight Loss – The latest Trends In Indian Automotive Market
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Responses to the challenge
• Vehicle Propulsion Technology
– Biofuel
– Natural Gas Vehicles
– Hybrid Electric Vehicle (HEV)
– Fuel Cell Vehicle (FCV)
– Battery Electric Vehicle (BEV)
– Spark Ignited Internal Combustion Engine (SIE)
– Transmission Improvement
• Driveline optimization
• Improved Tire Rolling Friction
• Vehicle Design
– Aerodynamics improvement
– Weight Reduction without compromising on safety & comfort
• Vehicle Downsizing
• Vehicle Design Change
• Selection of Lighter Materials
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Material Weight Reduction
-100 Kg -0.35 l/100km -9.0 g/km
Owens Corning estimates:
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Composites in Automotive Segment
188/1/2012
Replacing Traditional Materials
Global Materials Market(metric tonnes)
Source: Industry Statistics; E-Composites; Owens Corning Management Estimates
Wood
Steel
Composites
1.5% Aluminum Plastics
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Materials in Automobile
• Light-Weight Alternative Materials
• More than 2/3 of car weight is steel
Steel = Material of Choice in Auto
Industry
– Easily Available
– Stiff & Strong
– Easy to form
– Cost affordable
BUT…
Heavy (mild steel density: 7.86 g/cm3)
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Plastics…Low Density (Light)
Corrosion Resistance
Allow Complex Shape
Diversity of Process & Materials
Non-Conductive
Low Strength
Low Modulus
Poor Dimensional Stability
Steel…High Modulus
Moderate Strength
Dimensional Stability
High Density (Heavy)
Corrosion
Limited Choice of Processes
Conductive
Composites…Low Density (Light)
Corrosion Resistance
Allow Complex Shape
Diversity of Process &
Materials
Non-Conductive
High Strength
Dimensional Stability
Modulus: Medium to High
From Plastics to Composites
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SMC & BMCCommon Applications
SMC Tailgate
SMC Decklid
Structural
application
Under the hood
applications•Rocker Cover
•Manifolds
•Oil sump
Head Lamp
Reflectors
Pump housings
SMC
BMC
• Injection Molded Valve
Covers
• Circuit breakers
• Electrical insulators
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Surface Aspect Improvement Technology (SMC)
• Vacuum Assisted Molding (Budd)– Advantages
• De-gazing
– Eliminate porosities
• Increase of Surface Charge
– Reduction of long length waviness
• Low Pressure Molding –LPMC (Crystic Impreg®) – High-Flow Resin system
– 40 bars (instead of 85 bars)
• Tough Class-A SMC (Atryl® Resin)– Low porosity
• Minimization of Paint-Pops
– Less Micro-crackings
Crystic Impreg® is a trademark of Scott
Bader Corporation
Atryl® is a trademark of AOC Corporation© Domofon / shutterstock.com
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Material Thickness
[mm]
Weight
[kg]
Material
cost /
Part
Invest Total cost per
Assembled
Part
Integration
of
Functions
Steel 0.8 8.7 (100%)
100% 100% 100% Low
Aluminium 1.55.9
(70%)125% 125% 115% Low
Magnesium 2.0 5.2(60%)
225% 150% 175% Low
Composite(GMTex®)
2.5 – 3.5 4.5(50%)
125% 60% 80% High
Weight Reduction Success Story –Spare Wheel Well
GMTex® is a trademark of Quadrant AG
High Level of Function Integration allows Weight Reduction
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Cost Comparison
• Further Costs Reductions brought by Composites
– Handling Cost
• Less Parts Defects due to Dents & Corrosion
– Assembly Cost
• Parts Consolidation. Savings in Assembly Cost
• Part Manufacturing
– Part Cost strongly depending on
Processing Technique
– Better Cost Positioning for
Composites vs. Steel in Low &
Medium-Series models
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Advantages of Composites in Auto parts manufacturing
• Part weight reduction vs. steel
• Exceptional surface finish
• Functions integration
• Corrosion free
• High-thermal resistance
• Comfortable Ride
– Noise
– Vibration
– Harshness
©Maksim Toome / shutterstock.com
Battery
Cover
Engine Cover
Front-End
Module
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Cost Reduction (Fuel consumption & Maintenance)
Clean (CO2 Emissions)
Safety (Cockpit Protection, Part Integrity, Pedestrian Safety)
Comfort (Interior Space, Vibrations & Acoustics')
Personalization (Design, Flexibility Offer, Customization)
Why More Composites? The End-user’s Choice
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Thank you…
© 2012 Owens Corning, All rights reserved.
www.composites.owenscorning.com