Composites Use In Heavy TruckComposites Use In Heavy Truck Ed ZenkEd Zenk Composite Materials Engineer, Composite Materials Engineer,

International Truck & Engine Corp.International Truck & Engine Corp.

Current MaterialsCurrent Materials

Spray-up/lay-upSpray-up/lay-up Cold moldCold mold SMCSMC RTMRTM

Parts Using CompositesParts Using Composites RoofsRoofs HoodsHoods FairingsFairings DoorsDoors BumpersBumpers ReinforcementsReinforcements

Differences with Differences with automotiveautomotive

Larger partsLarger parts Severe service applicationsSevere service applications Lower volumesLower volumes Cosmetics (colors, surfaces)Cosmetics (colors, surfaces)

New Materials/ProcessNew Materials/Process

LPSMCLPSMC UV Cured materialsUV Cured materials

Advanced Composites (Carbon fiber)Advanced Composites (Carbon fiber) Dicyclopentadiene (DCPD)Dicyclopentadiene (DCPD)

New ApplicationsNew Applications

FramesFrames CabsCabs Under-the-hoodUnder-the-hood

Advantages

•Balanced Mechanical Properties

•Low Temperature Impact to –40°F

•Excellent Dimensional Stability

• -20°F to 175°F

• Nonmoisture Absorbing

•Outstanding Surface Replication and Paint Adhesion

• 98+ D.O.I.

• 5B Crosshatch Index

•Standard Two Component Urethane

•Light Weight – 1.03 gm/cc

•Low Pressure Processing

•Large, Complex Part Capability

•Numerous Tooling Options

•Low Cost•Short Lead Time

Liquid Molded DCPD for Heavy Truck

Mechanical PropertiesMechanical Properties

 Property  ASTM Method

Value

Density, g/cm3 (lbs/in3) D792 1.03 (0.037)

24 Hr. Water Absorption D570 0.12%

Tensile Modulus, GPa (Ksi) D638 1.90 (275)

Tensile Strength @ yield, MPa (Ksi) D638 46.8 (6.8)

Flexural Modulus, GPa (Ksi) D790 1.88 (273)

Flexural Strength @ 5% strain, MPa (Ksi) D790 70 (10.1)

Yield Strain D638 4.7%

Rockwell Hardness D785 R114

Notched Izod Impact, J/m (ft-lb/in) @ 23C (73.4F) @-40C (-40F)

D256 460 (8.7)106 (2.0)

Compression Strength, MPa (Ksi) D695 58.4 (8.5)

Shear Strength, MPa (Ksi) D732 49.5 (7.2)

DTUL @ 264 psi, C (F) D648 108 (226)(3)

Glass Transition Temperature, C (F) DMA(4) >138 (>280)

Coefficient of Thermal Expansion, m/m/C (in/in/F) 

D696 87.8x10-6

(48.8x10-6)Dielectric Constant 60Hz @ 73F D150 2.66

Dissipation Factor 60Hz @ 73F D150 0.0006

Shrinkage in/in (mm/mm)   0.009

Poisson’s Ratio ()   0.39

Flame Class Rating(5) UL HB

Manufacturing ImprovementsManufacturing Improvements

90-95% FTQ vs. 60-70% on previous 90-95% FTQ vs. 60-70% on previous versionversion

Average of 1.5 passes through paint versus Average of 1.5 passes through paint versus 2.5 to 3 passes for previous version2.5 to 3 passes for previous version

Greatly reduced prep time in plant prior to Greatly reduced prep time in plant prior to paintpaint

Cost-1997Cost-1997

DCPD was 90.0% of HSU hood in piece DCPD was 90.0% of HSU hood in piece priceprice

61.3% increase in tooling cost61.3% increase in tooling cost Payback achieved in the fourth yearPayback achieved in the fourth year Annual Volume 3000 unitsAnnual Volume 3000 units

Cost-2000Cost-2000

DCPD was 70.0% of HSU hood in piece DCPD was 70.0% of HSU hood in piece priceprice

105.6% increase in tooling cost105.6% increase in tooling cost Payback achieved in second year Payback achieved in second year Annual volume 6000 unitsAnnual volume 6000 units

9200 - 9400 - 9900 HOOD PAINT - BOTH SHIFTS - ALL COLOURS

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9200 HOODS

9400 HOODS

9900 HOODS

LWR SPEC

9200 HOODS 5.33 6.09 5.19 5.04 4.82 4.82 4.82 5.00 4.59 5.08

9400 HOODS 4.84 5.02 4.95 4.46 4.41 4.16 4.39 4.69 4.48 4.60

9900 HOODS 3.72 3.82 3.60 3.37 3.16 3.08 3.54 3.33 2.97 3.40

LWR SPEC 4.00 4.00 4.00 4.00 4.00 4.00 4.00 4.00 4.00 4.00

HOOD FRONT

HOOD CENTER

HOOD REAR

FENDER LT FRT

FENDER LT CTR

FENDER LT RR

FENDER RT FRT

FENDER RT CTR

FENDER RT RR

HOOD AVG

Orange Peel by Product

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05/14/00 06/03/00 06/23/00 07/13/00 08/02/00 08/22/00 09/11/00

Date

Orange Peel

Linear (9900)Linear (9400)Linear (9200)Linear (Skirts)Linear (Roofs)