OPPORTUNITY AND CHALLENGES FOR AUTOMOTIVE COMPOSITE APPLICATIONS

Transcription

1 OPPORTUNITY AND CHALLENGES FOR AUTOMOTIVE COMPOSITE APPLICATIONS Dr. Hendrik Mainka Engineering & Planning Center - Innovations 1

2 Volkswagen Group : 12 brands > 335 models 2

3 Key Figures of the Volkswagen Group in 2015 Production plants Employees Production 119 worldwide 610,100 10,017,000 vehicles per year Ø 38,527 vehicles per working day 3

4 Production locations within Volkswagen Group Total: 119 USA 1 Mexico 3 Brasil 6 Argentinia 3 Production Locations, South Africa 4 India 5 1) Asian 5 China 19 Production Locations in Construction, 1) Asian: Malaysia, South Korea, Thailand, Taiwan Germany 29 Poland 8 Spain 4 Czech Republic 4 France 3 Russia 3 Sweden 3 Denmark 2 Italy 2 Netherlands 2 Switzerland 2 Slovakia 2 Belgium 1 Bosnia - Herzegovina 1 Finland 1 Great Britian 1 Austria 1 Portugal 1 Turkey 1 Hungary 1 4

5 Content 1. The Challenge of CO 2 -Reduction 2. Lightweight Construction in the Automotive Industry 3. Example for Lightweight Construction: Full Composite SUV-Tailgate 5

6 1. The Challenge of CO 2 -Reduction 6

7 Requirement to reduce CO2 emissions Example Germany Emission Source Greenhouse gas emissions in Germany per car 1) -200g CO 2 /mile 230g CO 2 /mile 193g CO 2 /mile 153g CO 2 /mile 30g CO 2 /mile Germany 2010 Germany 2015 Germany 2020 Germany ) 1) Source: McKinsey & Company, Ministry of Environment 2) Memorandum of Understanding, e.g. EU- and G8+5-Staates, Part of Copenhagen Accord

8 CO 2 - Emission Standards - Market-Specific USA Europe China CO 2 - consumption laws are market-specific and very inhomogeneous! In all markets CO 2 is a key issue 8

9 Consumption allocation 100% Consumption Friction / Electric 3% Rolling Ressistance 13% 42% Drive Train Aero dynamics 19% 23% 23% Weight causes about ¼ of fuel consumption Weight 9

10 Principle of weight spiral + kg large tank volume highperformance engine Convenience Safety Quality Legislation Interior body adjustment heavy chassis 10

11 Reversing weight spiral Component-/ functional integration Body adjustment New materials and processes Cost-/ weight optimisation Lightweight chassis Reduced tank volume Less performance weight reduction initiates secondary effects through entire vehicle kg Next vehicle generation 11

12 CO 2 -Emission reduction resulting from 100 kg weight reduction CO 2 -Emission reduction [gco 2 /mile] Agility and driving fun 5.6 gco 2 /mile 13.6 gco 2 /mile 1 0 Weight reduction without drive train compensation Weight reduction with drive train compensation (engine and gearbox) 12

13 2. Lightweight Construction in the Automotive Industry 13

14 Materials in the car body structure / body panels composite materials heat-formed steel ultra high strength steel aluminum steel today future 14

15 Composite materials and aluminum Sandwich panels composite materials e.g. sheet metal light metals e.g. aluminum, magnesium aluminum Fiber reinforced plastic Continuous fiber reinforced plastics with glass and carbon fiber Weight reduction in construction > 100 lb Optimized plastics Geometry, manufacturing, materials 15

16 Lightweight material properties and cost 100% 25 relative component weight for the same functions 75% 50% 25% Steel Source: N/EK-L; EKP lightweight steel construction -5 to -25% -40% Audi A8 Aluminium car body structure Magnesium -15% CFRP quasi-isotropic -20% VW XL1 car body structure CFRP -60% unidirectional qualitative cost 16

17 Approval process of fiber reinforced composites Components Structured Exterior Visible carbon Matrix systems Epoxy resins Polyurethane resins Poly Amides Additives Fibers Fiber types Fiber sizing Filament count Textile Consumption Dynamics 17

18 time Lightweight concepts for the future Lightweight construction and functional integration by hybridization Hybrid lightweight structures Functional hybrid structures Weight - optimized lightweight for mass Quelle: SLC Multi - material mix fiber Reinforced plastics for medium quantities Optimized aluminum / steel mixed construction today Carbon fiber reinforced plastics Small quantities Aluminum Aluminum/ steel Small to medium quantities Steel high volume source: Volkswagen AG quantity 18

19 3. Example for Lightweight Construction: Full Composite SUV-Tailgate 19

20 Vision : CO 2 reduction through lightweight construction Composite SUV tailgate for market NAR Weight similar to aluminum Cost comparable to steel Performance equal to metal Class-A Finish Build a material and process database Prototype in 2017 Strong North American Partnerships A VW designed/built in NA for the NA market (engineered and build in ) 20

21 Why in Tennessee? Capabilities ORNL*, UTK*, IACMI* and Georgia Tech Goal: Establishing development expertise in the USA Cooperation with Oak Ridge National Laboratory: Material development for lightweight construction Process development for lightweight applications and 3D Printing Cooperation local Universities in Tennessee Knoxville and Structural and crash simulation for lightweight construction Establishing of exchange program (PhD-Program with Volkswagen Group Research and UTK) Automotive Master Program in cooperation with University of Tennessee Cooperation Georgia Tech: Top ranked engineering school Material Genome Initiative Technology Square *Oak Ridge National Laboratory, University of Tennessee Knoxville Institute for Advanced Composite Manufacturing Innovation 21

22 IACMI Institute for Advanced Composite Manufacturing Innovation IACMI is a public-private partnership that will develop and deploy advanced composite manufacturing technologies Six core partner states: Tennessee, Michigan, Colorado, Indiana, and Kentucky IACMI headquarters in Knoxville, TN 159 member consortium Volkswagen is Premium Member $259 million total funds - $70 million DoE and $189 million from IACMI partner (e.g. $15 from Tennessee) 22

23 Lightweight Construction = Functional Integration Situation: Inner Shell: - 6 Individual Steel Components - Each is Welded to Main Inner Shell Outer Shell: - 4 Individual Steel Components - Each is Welded to Make Outer Shell - Spoiler Requires 2 Step Stamping The 2 Shells are Welded Together Targets: Weight reduction Cost reduction - part - Investment + tooling Speed/cycle time improvement Reduction of joining processes Increased recyclability (LCA) 23

24 Simulation/Modeling, Materials and Manufacturing Low Cost Carbon Fiber Glass Fiber Fast processing resins SMC Class A Automated Layup Cost efficient part design Manufacturing simulation Material database Lab Scale Lab Scale Materials Pilot Scale Production Scale Manufacturing Process Pilot Scale Production Scale Design and Simulation Technology Readiness 24

25 Thank you for your attention 25