Raisingperformancethroughfastprocessing 120419122759 Phpapp02

Advanced Materials
Raising performance and productivity in automotive composites
Quarter 1, 2014
Table of contents
Huntsman expertise and solutions
Composites in automotive
Pioneer in composite mass production

Composites applications in automotive
Improving performance
Improving properties
Liquid composites processes in automotive
Pioneer in standard RTM
RTM process
Araldite solutions for standard RTM
Case stories
Mass production solutions
Standard pressure vs. high pressure RTM

Wet compression molding process
Araldite solutions for mass production
Advanced Materials
Huntsman expertise and solutions

< Table of content
Huntsman expertise >
Automotive composites >
Pioneer in RTM >
Mass production >
First supplier qualified for mass production of carbon composites
1990 - 2010 : Pioneer in structural composites (monocoque chassis Lamborghini, McLaren, Mercedes SLR, BMW Z1)
2013 : BMW i structural composite parts
Part production efficiency
Fast and adjustable epoxy systems

Designed for HP-RTM and compression molding, with fast demolding stiffness development
Compatible preforming solutions
Simulation capability
Superior properties
High elongation at break

High stiffness
Sustainable footprint
Bio-based feedstocks utilization

Best-in-class energy management
Advanced Materials

< Table of content
Pioneer in RTM >
Mass production >
Drive shafts
Advanced Materials

< Table of content
Pioneer in RTM >
Mass production >
Leaf springs
Advanced Materials

< Table of content
Pioneer in RTM >
Mass production >
Trunk panel
(EES technology)
Advanced Materials

< Table of content
Pioneer in RTM >
Mass production >
Roof
Advanced Materials

< Table of content
Pioneer in RTM >
Mass production >
Indoor panel
(EES technology)
Advanced Materials

< Table of content
Pioneer in RTM >
Mass production >
Chassis
Advanced Materials

< Table of content
Pioneer in RTM >
Mass production >
Wheels
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
Bonnet
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
Pressure vessel
Advanced Materials
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< Table of content
Advanced Materials
Pioneer in RTM >
Mass production >
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Composites for improved performance

< Table of content
Weight
Lower emissions
Lower fuel
consumption
Pioneer in RTM >
Safety
Demonstrated in F1
vehicles
Mass production >
Design
Reduction in number
of parts (integrated
functions)
Aesthetic
Impact of visual
carbon surfaces
Higher pay loads for

trucking industry
Noise
Absorption
Advanced Materials
Health
No emissions
Life cycle
No corrosion
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Composites for improved properties

< Table of content
Pioneer in RTM >
Mass production >
Density
in g/cm3
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
Modulus
in MPa
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
Tensile strength
in MPa
Advanced Materials
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Liquid composites processes in automotive

< Table of content
Pioneer in RTM >
Mass production >
Complexity vs. production speed
Advanced Materials
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RTM process
< Table of content
Pioneer in RTM >
Mass production >
RTM principle
Main features and benefits
Design freedom
Short cycle time
Industrial process for medium volume car
part production
High quality reproducibility
Integrated function (eg. number of parts
reduction, metallic insert integration)
View the process video
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
Araldite epoxy systems selection(1) for standard RTM

Product
Mix viscosity
Conditions
(1)
Curing temperature
for immediate demolding
Recommended
post-curing conditions
Max Tg
after post-cure
Toughness G1C
after post-cure (2)
after 60 min cure time
after 30 min cure time
DSC mid point

C
J/m2
Unit
mPa.s
Araldite LY 3585 /
Aradur 5003-1
440 - 500
at 40C
60
80
2h at 120C
120 - 130
180 - 230
Araldite LY 1564 /
Aradur 5003-1
200 - 260
at 40C
60
80
2h at 120C
108 - 115
230 - 290
Resin XB 3518 /
Aradur 22962
300 - 400
at 30C
80
100
2h at 140C
125 - 135
150 - 180
Araldite LY 3585 /
Aradur 3486
280 - 380
at 30C
80
100
2h at 120C
100 - 110
250 - 300
Araldite LY 1564 /
Aradur 2954
200 - 300
at 40C
90
100
4h at 160C
143 - 148
150 - 180
Araldite LY 3585 /
Hardener XB 3473
700 - 900
at 40C
150*
160*
2h at 180C
185 - 194
190 - 220
More products are available under request I
Advanced Materials
(2)
* Demolding < 120C
Measured with post-cure
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< Table of content
Pioneer in RTM >
Mass production >
Preforming epoxy binder for RTM

Product Designation
Softening point
Conditions
Tg
Typical preforming cycle
DSC mid point
Unit
Araldite LT 3366
ca. 150
75 - 85
20 10 sec at 180 20C

+ cold stamping
Typical preforming conditions: cold pressing after infra-red heating
Advanced Materials
21
Araldite solution for BMW

< Table of content
Pioneer in RTM >
Mass production >
M3 roof parts
with Araldite XB 3523 / XB 3458
Benefits
Parts with combination of low weight, high stiffness and high dimensional stability
Fashion / aesthetics due to visibility of carbon fabrics structure
Class A finish
Low shrinkage
Advanced Materials
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Araldite solution for Lamborghini

< Table of content
Pioneer in RTM >
Mass production >
Aventador LP700-4s chassis

with Araldite XB 3518 / Aradur 22962
Benefits
Low viscosity during injection

Sufficient pot life
Medium to high reactivity
Low shrinkage (surface quality)
High mechanical properties (good balance Tg / toughness)
Good hot / wet properties
Advanced Materials
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Araldite solution for engine air box

< Table of content
Pioneer in RTM >
Mass production >
Engine air box

with Araldite LY 3585 / Aradur 3486
Benefits
High complex, lightweight part produced in a single shot injection

Inserts and internal auxiliary structures formed during RTM process
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
RTM principle
Design freedom
Short cycle time
Industrial process for medium volume car
part production
High quality reproducibility
Integrated function (eg. number of parts
reduction, metallic insert integration)
View the process video
Advanced Materials
25

< Table of content
Pioneer in RTM >
Mass production >
Low pressure: static mixer
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
High pressure: mixing chamber
* HP-RTM requires the use of internal release agent, which can either be pre-dosed in the resin or mixed as a third component directly in the mixing
chamber. FPL functional scheme: with courtesy of Cannon
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
Compared processing conditions

STANDARD RTM
Low pressure
FAST RTM
High pressure
Mixing configuration
Static mixer
Mixing chamber
Mixing pressure
< 15 bar
> 15 bar
Mold pressure
< 15 bar
> 15 bar
Typical total cycle time
> 15 min
< 15 min
Advanced Materials
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Wet compression molding process

< Table of content
Pioneer in RTM >
Mass production >
Wet compression molding principle
Very short cycle time

No injection step
Low investment vs. high pressure RTM
Suitable for simple part production
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
Preforming epoxy binders solutions for High Pressure RTM

Product Designation
Softening point
Conditions
Tg
Typical preforming cycle
DSC mid point
Unit
Araldite LT 3366
ca. 150
75 - 85
20 10 sec at 180 20C

+ cold stamping
Key features
Araldite LT 3366 is qualified for mass production of powdered fabrics and preforms thanks to
High softening point preventing ply to ply adhesion

Fast preforming cycle
Typical preforming conditions: cold pressing after infra-red heating
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
Production cycles comparison

Fastest HP-RTM solutions
Fastest wet compression molding solutions
Araldite LY 3585 /
Aradur 3475
Araldite LY 3585 /
Hardener XB 3458
(reference)
Araldite LY 3585 /
Aradur 3475
Araldite LY 3585 /
Hardener XB 3458
(reference)
Preform / fabric
lay-up set (1)
0.5 min
0.5 min
0.5 min
0.5 min
Mold temperature
110 - 115C
100C
120 - 140C
120 - 140C
Injection
up to 1 min
(small to large part)
up to 0.5 min
(small to medium part)
Cure
> 2 min
> 5 min
> 1 min
> 2 min
Demolding
0.5 min
0.5 min
0.5 min
0.5 min
Part production time

(minimum)
4 min
6.5 min
2 min
3 min
Reference: first generation solution qualified for the first CFRP mass production application (BMW i program)
(1) Includes
mold closure and vacuum
Advanced Materials
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< Table of content
Pioneer in RTM >
Mass production >
Araldite LY 3585 / Aradur 3475

Typical thermal and mechanical performance
Tensile modulus
Tensile strength
Neat resin
ISO 527-2
Tensile elongation
DMA Tg onset (2)
ISO 6721
CFRP
ILSS (3)
ASTM D2344
Araldite LY 3585 /
Aradur 3475 (1)
Araldite LY 3585 /
Hardener XB 3458 (1)
(reference)
2 700 - 2 900 MPa
3 000 - 3 100 MPa
75 - 80 MPa
75 - 80 MPa
8 - 10 %
4-6%
105 - 115C
93 - 103C
58 MPa
60 MPa
Key features
High latency during mold filling
Very fast cure and demolding stiffness development
High tensile elongation at break
Reference: first generation solution qualified for the first CFRP mass production application (BMW i program)
(1) Data
(3) 50K
generated with 2phr internal release agent I

UD, TVf 50%
Advanced Materials
(2) Torsion
mode, 2C/min, only Tg assessment on composites relevant since neat resins exotherm in molds
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Keep our products at your fingertips

View the brochure on SlideShare
Download our mobile apps on your smartphone
With this brochure get an overview of our

comprehensive range of Araldite composite
formulated systems.
With these apps select immediately the right:

Araldite industrial adhesive for your specific need
Araldite composite formulated system for your process / application
Access the product description or send us an email to request
the technical data sheet.
Araldite - Adhesives (Europe)
Download on iPhone | Android
Huntsman - Composite resins (Europe)

Download on iPhone | Android
Advanced Materials
33
For more information

www.huntsman.com/advanced_materials
advanced_materials@huntsman.com
Europe
Huntsman Advanced Materials (Switzerland) GmbH
Klybeckstrasse 200
P.O. Box - 4002 Basel
Switzerland
Tel. +41 61 299 20 41
Fax +41 61 299 20 40
Advanced Materials
34
Legal Disclaimer
Copyright 2014 Huntsman Corporation
or an affiliate thereof. All rights reserved.
The use of the symbol herein signifies the registration of the associated trademark in one or more, but not all, countries. While the
information and recommendations included in this publication are, to the best of Huntsmans knowledge, accurate as of the date of
publication, nothing contained herein is to be construed as a representation or warranty of any kind, express or implied.

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Advanced Materials

Raising performance and productivity in automotive composites

Pioneer in composite mass production

Pioneer in standard RTM

Mass production solutions

Standard pressure vs. high pressure RTM

Huntsman expertise and solutions

Huntsman expertise >

Automotive composites >

Pioneer in RTM >

Mass production >

First supplier qualified for mass production of carbon composites

Part production efficiency

Fast and adjustable epoxy systems

High elongation at break

Bio-based feedstocks utilization

Composites applications in automotive

Huntsman expertise >

Automotive composites >

Pioneer in RTM >

Mass production >

Composites applications in automotive

Huntsman expertise >

Automotive composites >

Pioneer in RTM >

Mass production >

Composites applications in automotive

Huntsman expertise >

Automotive composites >

Pioneer in RTM >

Mass production >

Composites applications in automotive

Huntsman expertise >

Automotive composites >

Pioneer in RTM >

Mass production >

Composites applications in automotive

Huntsman expertise >

Automotive composites >

Pioneer in RTM >

Mass production >

Composites applications in automotive

Huntsman expertise >

Automotive composites >

Pioneer in RTM >

Mass production >

Composites applications in automotive

Huntsman expertise >

Automotive composites >

Pioneer in RTM >

Mass production >

Composites applications in automotive

Huntsman expertise >

Automotive composites >

Pioneer in RTM >

Mass production >

Composites applications in automotive

Huntsman expertise >

Automotive composites >

Pioneer in RTM >

Mass production >

Composites applications in automotive

Huntsman expertise >