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The 8th International Conference on Flow Processes in Composite Materials (FPCM8) Douai, FRANCE - 11 – 13 July 2006
COMPOSITE MATERIAL PARTS
IN RENAULT CARS :
THE PAST, THE PRESENT AND THE FUTURE
Alain Giocosa – Renault General Manager of Polymers Engineering Department
Material Engineering Department
In this presentation, I would like to present some applications for composite materials (thermoplastic and thermoset) in Renault cars, especially for large series vehicles. My proposed outline is as follows: • First of all, I would like to make some comments on customer perception, based on an
ESTEL survey conducted of 400 new-car buyers and to give an overview of composite materials used in Renault cars.
• Then, I would like to spend some time explaining why composite materials have been used and where these materials have been used : that is to say the past situation since over 30 years.
• Next, I will give several examples of what Renault is using nowadays : the present and current uses and developments going on.
• Lastly, I will try to explain what will be the future of composite materials and what we need to increase new applications. - Customer perception : During the ESTEL survey 4 main questions were asked to customers :
1. “What score, on a scale of 1 to 10, would you give to plastics for different characteristics ?” (safety, reliability, corrosion …).
2. The same question for the same characteristics, but comparing steel, aluminum and plastic.
3. “Did exterior materials influence your choice of model ?” 4. “In the future, which materials do you think will be increasingly used for car
exteriors ?”
The answers show that the customer perception of different materials is quite reasonable, that materials are not the decisive factor to choose one car among another and that plastic is overwhelmingly seen as the material of the future, aluminum and especially steel are left far behind.
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The 8th International Conference on Flow Processes in Composite Materials (FPCM8) Douai, FRANCE - 11 – 13 July 2006
- Overview of composite materials in Renault cars : a breakdown of the different
materials used in a car will give an idea of the weight ratio of ferrous, non ferrous, mineral and organic materials used in an average car.
- Why composite materials have been used since 30 years ? The main reasons are : weight saving to reduce gas emissions and fuel consumption, safety, cost reduction and customer’s needs.
- Where composite materials have been used since 30 years ? Some examples of applications since 30 years will be described.
- The present and current uses and developments going on. A breakdown will show the main functions where composite materials are used today in a car and some examples will be outlined and explained. The current developments in composite materials will be discussed, especially the trend to go from current semi structural applications to structural applications : we need new composite materials, new composite manufacturing technologies and new composite design developments. An example of the development of a “high speed” RTM process will be given through the TECABS project.
- The future of composite materials : to increase the use of composite materials the part manufacturers will have to increase part quality, to have a better knowledge on composite material behavior, to improve manufacturing processes and to develop accurate calculation tools. On the other hand car manufacturers will have to work on how to introduce composite parts in the manufacturing car process and to develop joining technologies compatible with multi-material cars. Both we will have to work on recycling and waste management solutions.
In the conclusion, I will outline that the use of composite materials has increased by 200 % over 30 years, a strong potential still exists for structural parts but metallic materials, aluminum and magnesium, are severe competitors and that we have to overcome two main drawbacks of composite parts : recycling and cost.
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8th International Conference on Flow ProcessesIn Composite Materials - Douai
Composite material parts in Renault cars :the past, the present and the future
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 2
Summary
• Custumer perception of materials
• Overview of composite materials in Renault cars
• Why composite materials have been used since 30 years ?
• Where and how composite materials have been used since 30 years ?
• Main functions where composite materials are used today
• Current developments going on
• The future of composite materials : how to increase their use ?
• Conclusion
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 3
CUSTOMER PERCEPTION OF MATERIALSCUSTOMER PERCEPTION OF MATERIALS
99
8,58,5
88
7,57,5
77
6,56,5
66
5,55,5
55
4,54,5
GoodGood
BadBad
Safe
tySa
f ety
r esi
stan
cer e
sist
ance
Rel
iabi
li ty
Rel
iabi
li ty
Cor
r osi
onC
orr o
sion
Af te
r sal
esA
f ter s
ales
cost
sco
sts
Age
i ng
Age
i ng
Rec
ycl in
gR
ecyc
l ing
Aes
t het
i cA
est h
eti c
aspe
cts
aspe
cts
Tech
nol o
gica
l lyTe
chno
l ogi
cal ly
Adv
ance
Adv
ance
Noi
seN
oise
r edu
cti o
nr e
duct
i on
Fini
shi n
gFi
nish
i ng
qual
it yqu
alit y
owner of owner of ScenicScenic
owner of owner of EspaceEspace
owner of owner of other modelsother models
PLASTICSPLASTICSWhich mark would you give to plastics related to …?Which mark would you give to plastics related to …?
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 4
Which mark would you give to steel, Which mark would you give to steel, aluminiumaluminium, plastics related to …?, plastics related to …?
8,58,5
88
7,57,5
77
6,56,5
66
5,55,5
55
4,54,5
GoodGood
BadBad
Safe
tySa
f ety
r esi
stan
cer e
sist
ance
Rel
iabi
li ty
Rel
iabi
li ty
Cor
r osi
onC
orr o
sion
Af te
r sal
esA
f ter s
ales
cost
sco
sts
Age
i ng
Age
i ng
Rec
ycl in
gR
ecyc
l ing
Aes
t het
i cA
est h
eti c
aspe
cts
aspe
cts
Tech
nol o
gica
l lyTe
chno
l ogi
cal ly
Adv
ance
Adv
ance
Noi
seN
oise
r edu
cti o
nr e
duct
i on
Fini
shi n
gFi
nish
i ng
qual
it yqu
alit y
AluminiumAluminium
SteelSteel
PlasticsPlastics
CUSTOMER PERCEPTION OF MATERIALSCUSTOMER PERCEPTION OF MATERIALS
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 5
DID EXTERIOR MATERIALS INFLUENCE YOUR CHOICE OF MODEL ?DID EXTERIOR MATERIALS INFLUENCE YOUR CHOICE OF MODEL ?
NONO
QUITE YESQUITE YES
RATHER YESRATHER YES
RATHER NORATHER NO66%66%
8%8% 9%9%
17%17%
CUSTOMER PERCEPTION OF MATERIALSCUSTOMER PERCEPTION OF MATERIALS
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 6
IN THE FUTURE, WHICH MATERIALS DO YOU THINK WILL BE INCREASINGLYIN THE FUTURE, WHICH MATERIALS DO YOU THINK WILL BE INCREASINGLY USED FOR CAR USED FOR CAR EXTERIORS ?EXTERIORS ?
33 1616 81814848 3636 1616
8989 88 33
1515 84844040 16164444
3328286969
10104343
7373
242422
64643434 33 2020
1515 1212
Steel sheetsSteel sheetsAluminiumAluminium
PlasticsPlastics
Steel sheetsSteel sheetsAluminiumAluminium
PlasticsPlastics
Steel sheetsSteel sheetsAluminiumAluminium
PlasticsPlastics
BUYER OF MEGANE SCENICBUYER OF MEGANE SCENIC
BUYER OF ESPACEBUYER OF ESPACE
BUYER OF OTHER MODELSBUYER OF OTHER MODELS
more and moremore and more as muchas much without opinionwithout opinion less and lessless and less
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CUSTOMER PERCEPTION OF MATERIALSCUSTOMER PERCEPTION OF MATERIALS
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 7
Overview of composite materials in Renault cars
Ferrous materials
Non ferrous materials
Mineral materials
Organic materials
Weight ratio of materials in a car
Weight ratio of organic materials in a car
ElastomersTires Sealers
PlasticsThermosets &Thermoplastics
OthersPaintAdhesivesSealersFluidsCarpets
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 8
Why composite materials have been used since 30 years ?
Reduction of gaz emissions - Fuel consumption
– Reduction of CO2 emissions (CAFE)
Contribution to the reduction of vehicle consumption
Gain of composite materials = Reduction of vehicle weight100kg saved = Decrease of 0.4 l/100km (stabilized speed)
Source ACEA
110130150170190
1995
1997
1999
2001
2003
2005
2007
2009
Con
sum
ptio
n(g
CO
2 /km
)
140
184 182 179 174 170 166
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 9
Vehicle safety
– No damage at low speed crash (4km/h)
– New regulation concerning pedestrian impactLow pedestrian damage during crash
– Low repairing costs
Why composite materials have been used since 30 years ?
Removable crash area
Eabs
Fmax
D(mm)
Fave.
Total disp.
Energy absorption curve of a SMC/BMC Material
F(kN)
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 10
Cost Reductions
– Increase of version number per vehicle model
New Renault Megane : 5 different rear floor pans for 7 models
Reduction of the production volumes per model
– Low tooling cost ( for low to medium production volumes )
– Simplification of manufacturing processesNo machining processesMultifunctionnal parts
Why composite materials have been used since 30 years ?
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 11
Customer’s needs
– Low cost in use
– Safety, Comfort, ReliabilityIncrease of constructor warranty (2 years --> 12 years)Fatigue properties increased with composite materials
– Image and new services
Vel Satis tailgate Renault Kangoo : under roof boxes
Why composite materials have been used since 30 years ?
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 12
MOSAIC Project 1994
Aluminum space frameExtrusion and cast nodeComposites Integrated panelsRiveting + Adhesive bonding
Weight saving 20%Overcost 20-40%
Where and how composite materials have been used since 30 years ?
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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Where and how composite materials have been used since 30 years ?
R15, bumperR5, bumpers & trims
R14, bumpers
Fuego, bumper R25, bumpers & trims
SMC bumpers evolution
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 14
Where and how composite materials have been used since 30 years ?
Espace 2
Avantime
Espace 3 (except bonnet)
Alpine A610
SMC body panels painted at low temperature
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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1983 - SMC body panelsPainted at low temperature
Espace
2000 - SMC tail gatePainted off line
Laguna 22001 - SMC fenders
Painted on line
VelSatis
1972 - Bumpers & trimunpainted part
R5
SMC/BMC components evolution
Where and how composite materials have been used since 30 years ?
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 16
Where and how composite materials have been used since 30 years ?
Trafic rear spring leaf :- Weight saving : from 15 to 20 kg,- Same cost / double steel spring leafs- pre-preg epoxy glass LF (50/50 vol).
New transversal front suspension :- epoxy – glass fabric,- “High speed” RTM.
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 17
Today’s distribution of composite materials in a car
• Interior accessories 50%
• External accessories 20%
• Under hood applications 15%
• External body panels 10 - 15%
• Structural applications 0 - 5%
Main functions where composite materials are used today
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 18
Composite materials for interior applications
Dash board structureTP + fillers or GF
Clutch pedalPA +GF Roof panel
PP + Nat. Fib. or GF
Door panelTP + Wood
Main functions where composite materials are used today
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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SMC fendersMedium production volume cars
ThermoPlastic fendersHigh production volume cars
Main functions where composite materials are used today
Composite materials for exterior applications : SMC and TP fenders
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 20
Main functions where composite materials are used today
Thermoplastic fenders across the range
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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Composite materials for exterior applications : SMC / BMC tailgates
Megane cc
Main functions where composite materials are used today
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 22
Main functions where composite materials are used today
Composite materials for exterior applications : Scénic RX4 hybrid tailgate
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 23
Main functions where composite materials are used today
• Skin panel painted Polypropylene (same as bumper)
• Inner panel GF reinforced PP – grained andbulk colored
• Additional element PP – grained and bulkcolored (same as interior panels).
Composite materials for exterior applications : Modus split tailgate
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 24
Composite materials for under the hood parts
Air filterPA+GF
Under engine protectionPP + GF Intake manifold
PA + GFCost reduction : 30%
Weight reduction : 30%
Main functions where composite materials are used today
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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Composite materials for structural parts
Main functions where composite materials are used today
Technical front end (Mégane 2)PA+GF
+ Steel structure
Rear floor pan (Mégane 2)Low density SMC
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 26
Main functions where composite materials are used today
BC84Rear overhang : 742mm
J84Rear overhang : 723mm
R84Rear overhang : 906mm
Steel reinforcedB84 LPG
ELK84Rear overhang : 970 to 991mm
Rear floor pan modularity (Mégane 2)
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Current developments going onC
ompo
site
mat
eria
l app
licat
ion
perf
orm
ance
s
Manufacturing process
developments
High speed production process for structural parts
Composite material
developments
Improvement of material properties
New composite design
developments
Part design and calculation tools
Current semi structural
applications
Structural applications
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 28
Current developments going on
Com
posi
te m
ater
ial a
pplic
atio
n pe
rfor
man
ces
Manufacturing process
developmentsComposite material
developments
New composite design
developments
Current semi structural
applications
Structural applications
Composite material developments
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 29
New composite materials : Targets
– Costs effective parts
– Improvement of composite part properties
– Introduction of composite parts in the car manufacturing process
E coat curing175°C / 195°C
Paint curing160°C
On line In line Off line
Current developments going on
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 30
New composite materials : Some examples
– Composite materials reinforced with nano fillersIntroduction of mineral nano fillers or carbon nano tubes in TP matrix
Semi structural applications (body panels, under the hood parts)
– Composite materials reinforced with natural fibersIntroduction of natural fibres (Hemp, flax ...) in TP and thermoset matrix
Semi structural applications (Interior applications)
– Composite materials reinforced with carbon fibersIntroduction of short carbon fibres, or carbon fibre fabrics
Structural parts (floor pans, cross beams, Body In White parts …)Semi structural parts (openings)
Current developments going on
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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Current developments going onC
ompo
site
mat
eria
l app
licat
ion
perf
orm
ance
s
Manufacturing process
developmentsComposite material
developments
New composite design
developments
Current semi structural
applications
Structural applications
Manufacturing process
developments
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 32
New composite manufacturing technologies : Targets
– Cost effective processIntegration of functionsWaste reduction
– Production of structural composite partsUse of long fibre reinforcements and fabrics
– At least medium production volumes (100 - 700 parts / day)
– Production of high quality composite parts
Current developments going on
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 33
New composite manufacturing technologies : Research area
– Manufacturing processNew manufacturing toolsImprovement of process parameters
– Process calculation toolsSelection of the best manufacturing strategyReduction of development durationReduction of prototyping step
– Improvement of material processabilityResin reactivityFabric drapability
Current developments going on
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 34
New composite manufacturing technologies : Development of a «High Speed» RTM process
– High fibre ratio (up to 50%)
– Use of carbon fibre reinforcements
– Complex shape : part with hollow cores
– Improvement of injection step
– Improvement of resin curing
– Production time < 10 min
Current developments going on
Part developed in the TECABS project
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 35
New composite manufacturing technologies : Process calculation tools
– Material behavior descriptionDefinition of local material properties
– Strong impact of part structureGeometrical singularitiesStructural singularities (sandwich structures ...)
– Influence of material properties evolutionsViscosity,Fibres / matrix segregation (SMC)
From TECABS project
Current developments going on
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 36
Com
posi
te m
ater
ial a
pplic
atio
ns p
erfo
rman
ces
Manufacturing process
developmentsComposite material
developments
New composite design
developments
Current semi structural
applications
Structural applications
New composite design developments
Current developments going on
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 37
– Lightweight innovative composite parts
– Increase performance part versus metallic solution
– Improvement of calculation tools for designing composite parts
Current developments going on
New composite design developments : Targets
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 38
Tailgate with carbon fibre reinforced materials
Structural rear floor pan
Weight saving (%) Steel version Ref SMC reinforced GF version 15% SMC reinforced CF version 25%
Weight saving (%) Cost Steel version Ref 1 Metal / composite version 15% 1 Composite reinforced GF version 38% 1.2 Composite reinforced CF version 47% 2.2
Current developments going on
New composite design developments :
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 39
– Virtual validation of composite part behaviorStatic behaviorDynamic behavior
Ex : Composite LPG tank
Burst testImpact at 50km/h on an edge simulation
Current developments going on
New composite design developments : calculation tools
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 40
The future of composite materials
0
100
200
300
400
1980 1990 2000 2010Year
Wei
ght o
f pla
stic
in R
enau
lt ca
rs
(kg)
Composite material weight in the future
Trend of composite materials evolution in the automotives
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 41
The future of composite materials
• Improvement of part qualityImprovement of surface aspect for body panels applications
(SMC parts)
• Better knowledge on composite material behaviorDynamic behaviorDurability
• Manufacturing processesReliable manufacturing processGood part quality
• Accurate calculation toolsOverall trend : increase of virtual prototypes
How to increase the use of composite materials ?
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 42
• Introduction of composite part in the manufacturing car processNo influence on the manufacturing car process
• Development of multi-material joiningStrong joining for structural applicationsRemovable assembling techniques (After Market ...)
• Reduction of material costsCase of High Tow Carbon Fibres
Today : 12 - 17 Euros / kgFuture : 8 - 10 Euros / kg ??
How to increase the use of composite materials ?
The future of composite materials
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DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 43
• Recycling Aspects
– End of Life Vehicle (ELV) European directive for 2015
• 95% of the vehicle by weight should be re-used or recovered• 5% of vehicle by weight could go to landfill• 10% of vehicle by weight could be incinerated
– Development of recycling and waste management solutionsCost effective recycled materialsCost effective waste treatments
The future of composite materialsHow to increase the use of composite materials ?
DREAM – DIMat – A. GIOCOSA – 11/13 Juillet 2006 P / 44
Conclusion
• The use of composite materials has increased by 200% over 30 years.
• A strong potential still exists for structural parts but the introduction of composite materials is difficult.
• The introduction of composite materials in a new vehicle project is long : complete development needs 10 years.
• Steel, Aluminum, Magnesium, are severe competitors of composites.
• The choice of a car manufacturer takes into account the part requirements and costs and NOT the material.
The 8th International Conference on Flow Processes in Composite Materials (FPCM8)Douai, FRANCE - 11 - 13 July 2006
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