JEC COMPOSITES MAGAZINE - Issue #55 - February/March 2010 - 14

INNOVATIONS in partnership with JEC Composites E-letter INNOVATIONS ContiTech and BASF reach new milestone in lightweight construction New applications for lightweight components are constantly being found in the automotive sector. For the first time, a transmission cross beam made of polyamide has been manufactured and used as standard in the new BMW 5 Series Gran Turismo 550i. By choosing Ultramid® A3WG10 CR (a 50% glass fibre-reinforced polyamide 66) instead of aluminium, it was possible to reduce the part weight by 50%. The transmission cross beam – a structural component designed to withstand high loads – is the direct link to the enginetransmission mount. It contributes to the overall rigidity of the vehicle and supports the forces and torque of the engine-transmission unit. ContiTech produces the component from exceptionally strong polyamide in an injection moulding process. With the help of BASF’s Ultrasim™ development instrument, it was possible to reduce the weight by 1 kg compared with the same component made of metal. In addition to weight reduction, development focused on optimum vehicle acoustics and crash safety. As proven by elaborate testing, these two goals were achieved. www.basf.com Rhodia committed to simulating engineering plastics as predictively as steel Rhodia has added three new functionalities to its technology for predicting the mechanical behaviour of reinforced polymers: MMI Confident Design™ (Multi-scale modelling / Mechanical calculation / Injection moulding simulation). This technology is capable of precisely calculating the mechanical properties of fibre-reinforced polymers. Rhodia has thus made a firm commitment to simulating engineering plastics as predictively as steel. The ability to accurately describe the behaviour of short fibre composites results from combining e-Xstream Engineering’s Digimat® software application with complex behaviour laws developed by Rhodia. Rhodia introduced three initial functionalities that provide information on behaviours under stress: elasticity, elasto-plasticity and elasto-viscoplasticity related to the speed of deformation. More complex functionalities will follow. To model behaviours, Rhodia went far beyond gross test results and used the best available resources, including microstructural analysis in collaboration with the synchrotron facility in Grenoble, advanced mechanical characterization at high speed, and videometric control of deformations. The initial applications are intended for the automotive industry. www.rhodia.com BMW M-Series carbon-fibre roof HexForce® NC2® reinforcements have been selected by BMW for the inner structural layer of the carbon-fibre roof of its M-series cars. Hexcel’s NC2® patented technology makes it possible to produce carbon-fibre multiaxial reinforcements that are flat, lightweight and provide more uniform coverage than conventional non-crimp fabrics. This is a major advantage when producing thin composite structures requiring a cosmetic appearance. HexForce® NC2® is a non-crimp technology that provides strength and stiffness exactly where required, taking advantage of unidirectional tapes that are joined by a novel stitching technology. NC2® allows great flexibility of fibre orientation with unmatched widths (up to 2,500 mm) and width adjustment capabilities. In addition, Hexcel has been supplying BMW for several years with HexForce® PrimeTex™ 3K spread fabrics for the outer skin of the carbon-fibre roof. Hexcel’s unique weaving experience combined with the new spreading technology allows the aesthetic specifications of BMW to be met. HexForce® PrimeTex™ fabrics have been processed to provide a very close weave and uniform cosmetic appearance. Hexcel has patents covering its innovative spreading processes. Supplying products tailored to the requirements of the M-series roof was challenging for 3 main reasons: very specific reinforcement widths, tight thickness tolerances, and large volume production are required. To focus on the challenges and meet the growing demand for composites in high-performance industrial applications, like the BMW M-series, Hexcel has formed a dedicated European business group. The new group has been established to maximize growth opportunities by optimizing Hexcel’s products and capabilities so that they meet the special requirements of performance-driven industrial markets including automotive and alternative energy. www.hexcel.com NRC and Magna to develop ultra-light materials for next-generation vehicles A new innovative partnership between Magna International Inc. and National Research Council Canada (NRC) will support the Canadian auto industry in developing next-generation vehicles. As part of the collaboration agreement, the Magna-NRC Composite Centre of Excellence will be created at the Magna Exteriors and Interiors facility in Concord, Ontario. It will be equipped with leading-edge moulding equipment for thermoplastic composites. This will provide teams from Magna and NRC with the tools needed to work together on developing lightweight and durable automotive parts using composites such as direct long fibre thermoplastics (DLFT) and sheet moulding compounds (SMC). These technologies have been identified as the best prospects for reducing the weight of structural car parts, making them more fuel-efficient and affordable. Joint project work in composites has already begun, while the new research facility is expected to be operational in summer 2010. www.nrc-cnrc.gc.ca 14 jec composites magazine / No55 February - March 2010

http://www.basf.com http://www.rhodia.com http://www.hexcel.com http://www.nrc-cnrc.gc.ca

JEC COMPOSITES MAGAZINE - Issue #55 - February/March 2010

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - Issue #55 - February/March 2010