Higher Temperature PP-Based Composite Provides Nylon/PA- Level Performance at Lower Weight and Economic Feasibility Society of Plastic Engineers Automotive Composites Conference & Exhibition September 13, 2012
Agenda ALBIS Group Mega-Trends and Market Drivers Performance PA GF / PP GF / PP LFRT next PP- NewTechnology next PP - Development Process Performance of next PP GF 35 next PP GF 35 - Aging Tests Drop-in solution / Warpage Target Applications Current Status Test Summary 2
ALBIS Group Facts & Figures Holding Foundation Turnover 2010/2011 Customers Employees Subsidiaries Compounding Sites Compounding Capacity Compounding Lines Certification ISO-9001 / ISO-TS 16949 OTTO KRAHN GmbH & Co. KG 1961 649/733 Mio. EUR approx. 10.000 923 16 3 130.000 t/p.a. 42 1995 / 2005 3
ALBIS Group Global Network 4
Mega-Trends and Market Drivers Motivation for Material Substitution Weight reduction Lower density Lightweighting Improved fuel efficiency Vehicle Fuel efficiency CO2 emission reduction and higher MPG Economic feasibility Avoidance of Penalties (excess CO2 emissions) Material cost reduction (PP is lower cost base resin vs PA) Processing cost reduction with PP vs. PA No pre-drying necessary Lower processing temperatures use less energy and faster cycling Material Availability Broad supplier base for PP feedstock Better global availability of PP vs. PA 5
Mega-Trends and Market Drivers Vehicle Emission Standards European Union-Emission Standards (EC)443/2009: Target of 130g CO2/km for 2012 phase-in basis between 2012 & 2015 2012 65% 2013 75% 2014 80% 2015 100% Penalties effective 2015: +1g 5,-Euro/car +2g 10,- Euro/car +3g 45,- Euro/car +4g 155,- Euro/car +5g 240,- Euro/car effective 2019: +1g 95,- Euro/car Target of 95g CO2/km for 2020 (to be reviewed in 2013) Source: Broschure Worldwide Emission Standards and Related Regulations, Continental Automotive GmbH, 3-2012 New emission standards drive weight reduction. 6
Mega-Trends and Market Drivers Emission Standards Penalties Source: Report How clean are Europe s cars?, European Federation for Transport and Environment (T&E), 9-2011 If Daimler, Volvo, BMW are not fulfilling Emission Standards they could face severe penalties as of 2015, i.e. +15g @Daimler would result in ca. 1,000,000,000 Euro 7
Mega-Trends and Market Drivers Emissions Reduction Impacts Design What does all this mean for Car Manufacturers / Suppliers? Weight reduction Metal replacement Lower density polymers/ fillers (e.g. PA=>PP, hollow glass) Carbon fibre technology Foaming, gas-injection, etc. Electrification Supercredits (<50g cars, equal 3,5cars) Electrical performance, high voltage Downsizing, i.e. smaller, powerful engines Mechanics Heat / creep resistance Aggressive liquids, i.e. fuels, lubes, etc. Chemical resistance Biofuel resistance (E10, E85) Market Driven vs. Customising. New Product Designs 8
Mega-Trends and Market Drivers Growth of Plastics Usage [kg] 300 250 200 Growth of plastics usage in cars 190 kg 235 kg 250 kg 150 129 kg 134 kg 100 50 0 93 kg 12 % 14 % 12 % 15 % 16 % 20 % 1974 1983 1991 1997 2003 2008 Golf I Golf II Golf III Golf IV Golf V Golf VI Source: VDI - Plastics in Automotive Engineering, Mannheim, 21.-22.03.2012 Weight and cost reduction drive increased use of plastics. 9
Mega-Trends and Market Drivers Inter-Polymer Competition Substitution chain in the plastics industry Current status next PP close the gap 10
Performance PA GF / PP GF / PP LFRT Current Status Properties PP-H GF30 PA6 GF30 PP LFRT 30 Density [g/cm³] 1,12 1,36 1,12 ISO 1183 tensile strength [MPa] 23 C 55 110* 110 DIN EN ISO 527 E-Modul [MPa] 23 C 5500 5500* 6300 DIN EN ISO 527 elongation at break [%] 23 C 2 5* 2,3 DIN EN ISO 527 E-Modul [MPa] 75 C 3200 4500* 4600 DIN EN ISO 527 E-Modul [MPa] 120 C 1750 3800* 3500 DIN EN ISO 527 HDT A [ C] 138 >200 156 DIN EN ISO 75 Flexural strength [MPa] 75 175* 147 DIN EN ISO 178 Charpy unnotched [kj/m²] 23 C 12 70* 52 Charpy notched [kj/m²] 23 C 5 11* 19 DIN EN ISO 179/1eU DIN EN ISO 179/1eA Flow spiral [mm] 750 650 550 ALBIS Norm * conditioned 11
next PP - New Technology A technical alternative to PA6 and PP LFRT compound Based on low cost, approved Polypropylene matrix New innovative technology Closing the gap between commodities and engineering resins 12
next PP - Development Process 15 months development time Approx. 190 production runs on laboratory extruder in R+D Formulation development Processing development Determination of mechanical properties through internal and external laboratory 9 Production trials Scale up Processing development Optimazation dosing position and units Optimazation screw design Maximization throughput 13
Performance of next PP GF 35 E-Modulus vs. Temperature E-Modul [MPa] 8000 7000 6000 5000 4000 3000 2000 PA6 GF30 (cond.) next PP GF35 PP-H GF30 PP LFRT 30 1000 20 40 60 80 100 120 Temperatur [ C] Up to 110 C very similar to Nylon and PP LFRT 30 14
Performance of next PP GF 35 Benchmark I Properties PP-H GF30 PA6 GF30 PP LFRT 30 next PP GF 35 Density [g/cm³] 1,12 1,36 1,12 1,18 ISO 1183 tensile strength [MPa] 23 C 55 110* 110 100 DIN EN ISO 527 E-Modul [MPa] 23 C 5500 5500* 6300 8300 DIN EN ISO 527 elongation at break [%] 23 C 2 5* 2,3 3 DIN EN ISO 527 E-Modul [MPa] 75 C 3200 4500* 4600 4900 DIN EN ISO 527 E-Modul [MPa] 120 C 1750 3800* 3500 3000 DIN EN ISO 527 HDT A [ C] 138 >200 156 154 DIN EN ISO 75 Flexural strength [MPa] 75 175* 147 140 DIN EN ISO 178 Charpy unnotched [kj/m²] 23 C 12 70 52 50 Charpy notched [kj/m²] 23 C 5 11 19 10 DIN EN ISO 179/1eU DIN EN ISO 179/1eA Flow spiral [mm] 750 650 550 940 ALBIS Norm * conditioned 15
Performance of next PP GF 35 Benchmark Il Flow spiral E-Modul 23 C 200% 180% 160% 140% 120% E-Modul 75 C next PP 30 PP LFRT 30 PA 6 GF 30 con. 100% Charpy notched 80% 60% E-Modul 120 c 40% Charpy unnotched tensile strength 23 C Flexural strength HDT A next PP shows comparable properties with better flowability 16
next PP GF 35 - Aging Tests Thermal Storage Tests Hot air storage (Ofen storage) E-Modul DIN EN ISO 527 tensile strength DIN EN ISO 527 [MPa] [MPa] 0h / 23 C 1000h / 130 C 0h / 23 C 1000h / 150 C 7920 8290 8255 8100 98 106 109 105 elongation at break [%] DIN EN ISO 527 Flexural modulus DIN EN ISO 178 Charpy unnotched DIN EN ISO 179/1eU Charpy notched DIN EN ISO 179/1eA [MPa] [kj/m²] [kj/m²] 3,0 3,0 2,7 2,6 6941 7684 7360 7570 55 55 52 48 10 10 11 11 No reduction of the properties after thermal storage 17
next PP GF 35 - Aging Tests Oil aging test Oil aging 100h @ 90 C Tensile Strength Un. Charpy (23 C) 120% 100% 80% 60% 40% 20% 0% E-Modul 23 C next PP GF 35 PA GF 30 VWRequirement Flexural Modulus Flexural Strength 18
next PP GF 35 - Aging Tests Glycol aging test Glycol aging 100h @ 90 C Un. Charpy (23 C) Tensile Strength 120% 100% 80% 60% 40% 20% 0% E-Modul PA GF 30 next PP GF 35 VW Requirement Flexural Modulus Flexural Strength 19
next PP GF 35 Drop-in solution / Warpage shrinkage PA 6 GF 30 next PP GF 35 longitudinal 0,16 0,4 transverse 0,82 0,6 averaged 0,49 0,5 Drop-in solution, due to comparable shrinkage Less warpage, due to smaller difference between longitudinal and transverse shrinkage 20
next PP GF35 Targets / Applications Main focus areas: 1. Automotive Under the hood 2. E&E engine cover, fan frame, fuse box, air intake manifold, etc. Power tools Appliances 3. General industries Furniture Other existing PA6 GF applications 21
next PP GF 35 Current Status Tests FMVSS 302 (flambility test) passed Shrinkage 60x60x2 mm 3 (parallel / transverse) 0,3-0,4 / 0,5-0,6 Glow wire test/ 650 C @ 1 mm - 4 mm passed GWFI IEC 60695-2-12 Emissions not finished Media storage not finished Scratch resistance test not finished 22
next PP GF 35 Summary Weight reduction (ca. -18% vs. PA) Economic feasibility Excellent HDT performance (HDT A = 154 C); PP GF 140 C, PP LFRT 156 C, PA GF > 200 C High stiffness (> 8000 MPa @ 23 C) Good aging properties Drop-in solution / Warpage Processing advantages (Flow spiral approx. 94 cm) Outstanding surface properties 23
Thank you for your attention! Jim Keeler, jim.keeler@albis.com