Novel Composite Materials for Demanding Automotive by kgp18294

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									Novel Composite Materials
for Demanding Automotive
       Applications
            ACCE
     September 12-13, 2006
Overview
•   Introduction
•   FRP Composite Attributes
•   Market Growth
•   Composite Properties
•   Conclusion
Introduction
• Objective: Develop an unsaturated polyester resin with thermal and
  chemical stability of vinyl ester resin.

• Targeted Applications: Under-The-Hood Automotive Components
   • Cam Covers
   • Valve Covers
   • Oil Sumps
   • Heat Shields
   • Engine Covers
FRP Composite Attributes
•   Weight Savings
•   Parts Consolidation
•   Thermal Stability
•   Chemical Stability
•   Design Freedom
•   Lower Costs
•   Lower NVH
                           UTH Volume Growth *
                                SMC/BMC
        40

        35

        30

        25
M lbs




        20
 M




        15

        10

        5

        0
             1996   1997    1998   1999   2000   2001   2002   2003   2006
                                   Year *(ACA DATA)
Development Plan
• Approach
   • Evaluate physical properties of different unsaturated polyester resin
     to vinyl ester resin blend ratios
      • As made
      • After 1000 hours 180°C heat exposure
      • After 1000 hours 150°C oil exposure
   • Determine optimum blend ratio
   • Evaluate physical property retention of optimal blend ratio after
     exposure to various automotive fluids
UTH Component Fitness-For-Use
• Thermal Stability at elevated engine compartment temperatures
• Chemical Stability against automotive fluids
• Aesthetics
                     Flexural Strength Retention

120.0%

100.0%

80.0%
                                                   Control
60.0%                                              Oil Aged (5W30 1000 hours @ 150°C)
                                                   Heat Aged (1000 hours @ 180°C )
40.0%

20.0%

 0.0%
         0     25           50           100

         100   75           50            0
                    VE:PE
                     Flexural Modulus Retention

120.0%

115.0%
110.0%
                                                  Control
105.0%
                                                  Oil Aged (5W30 1000 hours @ 150°C)
100.0%
                                                  Heat Aged (1000 hours @ 180°C )
95.0%
90.0%

85.0%
         0     25           50          100

         100   75           50           0

                    VE:PE
                     Tensile Strength Retention

120.0%

100.0%

80.0%
                                                  Control
60.0%                                             Oil Aged (5W30 1000 hours @ 150°C)
                                                  Heat Aged (1000 hours @ 180°C )
40.0%

20.0%

 0.0%
         0     25           50          100

         100   75           50           0

                    VE:PE
                     Tensile Modulus Retention

120.0%

100.0%

80.0%
                                                 Control
60.0%                                            Oil Aged (5W30 1000 hours @ 150°C)
                                                 Heat Aged (1000 hours @ 180°C )
40.0%

20.0%

 0.0%
         0     25           50         100

         100   75           50          0

                    VE:PE
                                        Flex Modulus Retention 1000 hours Exposure


120.0




100.0




80.0




60.0




40.0




20.0




  0.0
        150°C M otor oil   150°C Brake Fluid    150°C Transmission Fluid   93°C 1:1 Water Antifreze   38°C 90/10 Gasoline/Ethanol   38°C Diesel Fuel
                                      Flexural Strength Retention 1000 Hours Exposure


120.0




100.0




80.0




60.0




40.0




20.0




  0.0
        150°C M otor oil   150°C Brake Fluid    150°C Transmission Fluid   93°C 1:1 Water Antifreze   38°C 90/10 Gasoline/Ethanol   38°C Diesel Fuel
                                      Tensile Strength Retention 1000 hours Exposure


120.0




100.0




80.0




60.0




40.0




20.0




  0.0
        150°C M otor oil   150°C Brake Fluid   150°C Transmission Fluid   93°C 1:1 Water Antifreze   38°C 90/10 Gasoline/Ethanol   38°C Diesel Fuel
                                           Elongation Retention 1000 hours Exposure


140.0



120.0



100.0



80.0



60.0



40.0



20.0



  0.0
        150°C M otor oil   150°C Brake Fluid     150°C Transmission Fluid   93°C 1:1 Water Antifreze   38°C 90/10 Gasoline/Ethanol   38°C Diesel Fuel
Conclusions:
• A unique unsaturated polyester resin has been developed for UTH
  applications.
• This resin offers molders a lower cost option verses traditional vinyl ester
  resin systems.
• This resin has excellent thermal and chemical stability at elevated
  service temperatures.

								
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