LANXESS High Performance Materials Addressing The Trends In Automotive
LANXESS High Performance MaterialsAddressing the trends in automotiveJose Chirino, Technical Director, AmericasNational Academy of Science Webinar: Assessment of Technologies for Improving Fuel Economy of Light-Duty Vehicles – Phase 3May 17th, 2019
AgendaLANXESS OverviewPlastics & Composites for Global Fuel Efficiency Automotive TrendsLightweightingPowertrainAerodynamicsClosing Remarks2LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarMay 17th, 2019
LANXESS –A globally operating specialty chemicals Strategy ofprofitabilityand resilience3LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarSpin-off from Bayer in 2004Specialty chemicals portfolio:chemical intermediates, additives, specialty chemicals andplastics60 production sites worldwideApproximately 15,500 employees in 33 countriesGlobal sales of EUR 7.2 billion in 2018Strengthening of leading position in medium-sized marketsConsolidation in Europe, expansion in USA and AsiaMay 17th, 2019
High Performance Materials at a glance –Leading supplier of engineering plasticsKey figuresSites:Employees:Customers:Global Presence9 1,600 600BrandsPA6 and PA66PBTCOMPOSITESEngineeringApplicationsGlobal compounding networkMarkets4Automotive UTHAutomotive StructuralElectrical / ElectronicsAppliancesLANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarBackward integrated supplyProduct and applicationdevelopmentMay 17th, 2019
Typical Polyamide (“Nylon”) applications in AutomotiveWide range of lightweight and durable componentsFunctional areaAutomotive Components with LANXESS contributionCross car beamBody/StructureRoof/door frameFront endBracketAirbag housingFuel Delivery SystemActuator Housing5PulleysPedal / pedal bracketSeat panAir SystemsWindow SurroundRear Vision (interior)Motor HousingSteeringColumnSteering rodChassisModule/ElectronicsHousingsStructural insertGearbox oil panCylinder head coverDrivetrainDoor SystemsFan/ShroudEngine oil panInteriorSpare wheel wellAir Spring Systems Chassis Space FrameLANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarSteering Control SystemConnectors/HousingsMay 17th, 2019
AgendaLANXESS OverviewPlastics & Composites for Global Fuel Efficiency csPlastic & Composite Innovation Highlights6LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarMay 17th, 2019
Fuel EconomyFuel efficiency regulations are a global trendOEM StrategiesImproving Fuel tionAerodynamics7LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarMay 17th, 2019
LightweightingAcross all vehicle classesEntertainment, comfort & safety features all increasevehicle weight10% weight reduction improves fuel efficiency byestimated 6-8%Polymers make up 50% vehicle volume, but only 10%vehicle weight.Latest CFRP further reduce part weight by 70%Challenges:Weight reduction without negative effect onperformance, safety and cost.Metal replacement, as well as density reduction andthickness optimization of existing plastic partsTechnologies @ LANXESSHigh Modulus / High Flow materials for thinwallcomponents, including CF Polyamide and compositesPlastic Metal Hybrid for lighter components: Cross carbeam, Front End Modules,All plastic composite componentsNoise-Vibration-Harshness (NVH) considerations8LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarMay 17th, 2019
5003545030400253502030025015200101501005Weight Specific Strength (MPa/(g/cm3))Weight Specific Modulus (GPa/(g/cm3))Mechanical Properties of Metals vs. ThermoplasticsWeight Specific Comparison500Steelρ 7,8AluminumPA6GF60ρ 2,7ρ 1,7PA6CF30ρ 1,26PA6 GF Woven Sheet* PA6 CF Woven Sheetρ 1.80ρ 1.45* 47 vol.-%, dry, woven, 50/509LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarMay 17th, 2019
LightweightIncreasing requirementson stiffness (e.g. NVH)Technology Toolbox LANXESSPlastic Metal HybridHollow Profile HybridPlastic Composite Bumper BeamFull PlasticTepex Composite HybridIncreasing requirements on strength (e.g. crash)10LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarMay 17th, 2019
Lightweight Front EndUse of localized compositesSUV Front End ModuleTepex Composite TechnologyFree of sheet-metal – even at top cross-memberextending to the fender carriersWithstands hood latch and head lamp loadswithout sheet-metal reinforcement50% weight reduction vs SteelWall thickness 1.8 – 4 mmCost savings through smart use of composites:Localized Tepex composite only usedwhere it is needed.11LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarMay 17th, 2019
Lightweight examplesIn production today – Future developments ongoingRear BumperPart weight 3.6 kgWeight reduction 50 % vs aluminum/steelOne shot processMeets all US standards for rear crash performanceCross Car BeamHigh stiffnessFunctional integrationLightweightCost reductionMeets all US standards for crash performance12LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarMay 17th, 2019
PowertrainTurbo is here, Electrification is comingAir intake systemBlow-byPowertrain know-how is main focus for fuel efficiencyAccounts for 25% of vehicle massFuel delivery systemChassisTurbo charged and EGR (Exhaust Gas Recovery)bracketsCooling circuitPowertrain electrificationAirductsOil circuitGlobal PlatformsTechnologies @ LANXESSChallenges: Next Generation High Heat PA grades (“XTS”) for AIM. Increased engine temperatures Hot Side air ducts with improved heat stability Compact engine design High temperature Hydrolysis Resistant (HR) grades forcooling systems. Lightweight electric systems with new requirements:Cooling, flame resistant, EMS 13LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science Webinar Metal replacements in Engine and TransmissioncomponentsMay 17th, 2019
Battery System –Various applications for Engineering PlasticsCritical RequirementsCenter platesImpact / StrengthCable bracketsFlammabilityLightweightcoverSurface QualityDurabilityHV connectorsmodulecoverspacerhousingcooling systemBattery Management Systemprismatic battery cell14LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science Webinarend plateMay 17th, 2019
Improved AerodynamicsActive Grille Shutters (AGS) and Underbody ProtectionAerodynamics essential, even for EVsJust removing roof rack improves fuel economyby 5%AGS not implemented “across the board”Depends on engine size, fuel efficiency strategyImproves FE by 2g CO2/km 1.1 MPG (0.4 km/l)Challenges:Optimization of AGS (weight / flatness / strength)Underbody components with unique requirements:Impact resistance, engine accessibility, heatmanagement15LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarTechnologies @ LANXESSNew Extreme Flow PA grades for reduced warpage(BKV30XF) and improved cycle timesNext generation of UV-stable PA grades with improvedsurface qualityTepex composite sheet for underbody protectionMay 17th, 2019
Tepex compression molding (LWRT)Under body protectionDirect Compounded Long Fiber ThermoplasticCompression molding Low Weight ReinforcedThermoplastic LWRTTepex composite surface and metal inserts3 times higher strength and energy absorptionin comparison to other non-composite solutionImproved acoustics / sound absorptionImpact Resistant: excellent durability on roughroadsFast cycle times for mass production ( 1 min)16LANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarMay 17th, 2019
Polymer Materials Improving Fuel Economy17 Safely Reducing Weight Reducing Cost & Consolidating Parts Improving Aerodynamics Enabling Electrification & MoreLANXESS HPM: Automotive Lightweight Solutions - J. Chirino - National Academy of Science WebinarMay 17th, 2019
Across all vehicle classes Entertainment, comfort & safety features all increase vehicle weight 10% weight reduction improves fuel efficiency by estimated 6-8% Polymers make up 50% vehicle volume, but only 10% vehicle weight. Latest CFRP further reduce part weight by 70% Challenges: Weight reduction without negative effect on
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