LFT – development status

and perspectives
Prof. Dr Michael Schemme reviews long fibre
reinforced thermoplastics technologies and their
applications in the automotive industry.

ong fibre reinforced thermoplastics modules, hatchback doors, seat shells, The dualism of modern vehicle technology

L (LFT) have become well established

over the past 20 years as high per-
formance engineering materials for
structural applications in the automotive
industry. Apart from their excellent econom-
ic benefits and low weight, their big advan-
tage lies in a high level of productivity in
processing, which is a result of the short cycle
times attainable with thermoplastic matrix
systems. Other positive aspects include high
plant availability, consistently high quality,
the wide range of possibilities for integration
of different functions in a single component,
and the fact that the system costs can also be
lowered. These benefits have resulted in con-
stant growth for LFT, at a much higher rate
than with conventional materials. In view of
the European Union (EU)-ratified end-of-life
vehicle (ELV) directive, the unproblematical
recycling of LFT (compared with fibre rein-
forced thermoset matrices) is also becoming
an increasingly important factor.
In the past, the tendency was to use
LFT for more simple applications such
as covers or backing, or for parts in
unexposed areas, but with the arrival of
new material systems optimised for the
specific application, and with the ongoing
development of the processing and process
engineering, it has now become possible
to mass produce highly stressed structural
parts and innovative module systems with a
high level of functional integration. Current
examples of applications in the automotive
segment include instrument panel supports
(IPS), technical front-ends, door and roof
bumper supports, sound-absorbing shells,
spare wheel pans and – one of the fastest
growing applications – complete underbody
systems.
In the past, the tendency
was to use LFT for more
simple applications; it has
now become possible to
produce structural parts and
innovative module systems.
Table 1: The advantages and disadvantages of FRP with thermoplastic matrices
(as opposed to thermoset matrices).
Advantages
High durability (εB, impact resistance)
– strong damage tolerance
Low emissions (‘fogging’)
Low moisture sensitivity (except PA)
Short cycle times (no hardening reactions)
Unlimited shelf life without the need
for cooling
Thermal post-processing possible (welding,
re-forming etc)
Simple recycling (in-house)
with the growing use of lightweight
construction on one hand and with vehicles
getting heavier in every generation on the
other hand, is contrasted by clear ecological
parameters and limits, as can be seen in the
current discussion about the reduction of
carbon dioxide (CO2) emissions and the
call for limits set by law. The solution of
this conflict represents a big challenge for
the automotive industry and its partners in
the supply industry. A real reduction in the
weight of vehicles – without endangering
or even abandoning progress in safety and
comfort – can only be reached by the use of
new material concepts and manufacturing
Disadvantages
Processing-induced crystalline structure
(for partially crystalline thermoplastic)
– shrinkage and warpage
Reduced compression strength and stiffness
Difficult to impregnate due to high
melting viscosity
Interphase problems (fibre-matrix adhesion,
esp. for unpolar thermoplastic)
Paintability and glueability
High processing temperatures and pressures
Creeping (esp. at higher temperatures)

32 REINFORCEDplastics January 2008 0034-3617/08 ©2008 Elsevier Ltd. All rights reserved
 Feature

technologies. The automotive industry

Table 2: The history of the development of GMT.
has been very reserved towards the design,
from 1967 Development of the GPL (glass mat polypropylene laminate) in the USA
construction and selection of modern
(PPG/Union Carbide) – Azdel©
lightweight materials – materials which have
from 1970 Laboratory-scale production and processing
been widely accepted in other industries
are still waiting for their breakthrough in 1972 Market launch in the USA: coverings and shells (underside panelling,
battery pans and spare wheel pans)
the automotive world. A clear exception are
the glass fibre/polypropylene (PP) based 1975 First serial front-end/retainer (Chevrolet Monza)
LFT materials, which meet the demands of 1977 Front support frame (Pontiac Firebird, Chevrolet Camaro)
the automotive industry regarding system 1978 Seat pans (Chevrolet Corvette)
costs and mass production because of their 1978 Start of development work in Europe by Symalit and BASF – production
competitive prices and the cycle times which start in 1982
can be realised with thermoplastic matrices. 1982 First European serial implementation: simple parts eg. DC W 201
engine pan
Definitions from 1985 Widened serial implementation in the European automotive industry
1992 Technical front-end VW Golf III
The quality and mechanical properties of
an LFT material are defined by the basic 1997 Hatchback door DC W 168
materials (the matrix system and the type 2003 Hybrid hatchback door Nissan Murano
of fibre) but also to a very large extent 2004 Lightweight underbody systems of the BMW series: E 60/61, E 63/64,
by the process-induced flow orientations E 8x and E 9x
and the fibre lengths in the finished part.
The orientation and real fibre length are cussions are, of course, sometimes coloured new terms were coined in the specialist litera-
influenced significantly by the particular by the interests of the various material and ture, in the datasheets published by the raw
processing method and the variation process developers. The advantages and dis- material manufacturers, and in the process
of process parameters. The mechanical advantages of fibre reinforced plastics (FRP) descriptions issued by the machinery manu-
properties of real components are broadly with thermoplastic matrices (as opposed to facturers. Often such terms were not used
scattered as a result of the process-specific thermoset matrices) are given in Table 1. consistently to describe one and the same
plasticising and flow processes of the melt, Strong demands from the automotive material or process, and this has led to a real
the resultant fibre length reduction and the industry for cost savings have, in the last few confusion of terms and definitions, not only
orientation of the fibres. years, spawned a variety of new material and for the processors but also for the users.
The mechanical performance potential process developments in the field of LFT. As However, an initial, important step
of long fibre reinforced plastics is directly a result, a vast number of abbreviations and is the recent development of a standard
connected to the relative fibre length of
the reinforcing fibres used (Figure 2). The
aspect ratio is the ratio between the fibre Processing technology
Long fiber
fibre Thermoplastics
thermoplastics (LFT)
length and the fibre diameter. For glass fibres
with the usual fibre diameter of 12-14 µm a Compression
Compression Moulding
Moulding Injection
Injection Moulding
Moulding
CM
CM IM
IM
value of 100 corresponds to an effective fibre
length of 1.2-1.4 mm. The confusion was Sheet Compression Moulding Extrusion Compression Moulding Semi-finished material Direct process
(S) CM ECM LFG-IM D-LFT-IM
partly due to the fact that, in the case of LFT,
depending on which semi-finished product Compression moulding with material flow
(S) CM
Long Fibre Granulate process
LFG-ECM
Long Fibre Granulate
LFG-IM
Direct compounded raw material
D-LFT-IM
and processing method was used, there was GMT STAMAX, COMPEL,
mat-/ papertechnology TWINTEX, FACTOR STAMAX, CELSTRAN Krauss Maffei (IMC)
little consistency with regard to the fibre Quadrant / Azdel APPRYL, NEPOL TWINTEX, APPRYL, FACTOR ECIA (XRI)
8

(fiber length: > 25 mm/ variable) (fibre length: 12- 25mm) VERTON, NEPOL Husky /COPERION (W&P)
lengths in the finished part. (fibre length: 8-12 mm) (fibre length: variable)
Compression moulding without material flow Direct process
An unambiguous definition of the term (S) CM D-LFT-ECM

'long' – which is very relative indeed in the Hybrid-GMT: GMTex / TWINTEX Dieffenbacher (ILC),ECIA (XRE)
8

Uniderectional tapes, fabrics Krupp / W&P, JCI (Fibrolen)

PLYTRON/ FIBEROD /TEPEX/CURV
case of LFT – is a problem because, for exam- (fibre length: endless)
ple, a mean length of 2 mm is considered GMT- Papier-/ Vliestechnology
Symalite, Superlite
'relatively long' in the conventional injection (fibre length: ≈ 12-25 / 75 mm)
Lawton (KMH) / CPI
(fibre length: variable) Hybrid-Technologies
Combination of local reinforcements
Dieffenbacher (Tailored-D-LFT), (fabrics / unidirectional tapes)
ESORO / Weber (E-LFT) with standard LFT-processes
(fibre length: variable + continuous

moulding process, but 'relatively short' in the Figure 1: Classification of the manufacturing processes for long fibre reinforced thermoplastics. (Products, brand
compression moulding process. These dis- names and registered manufacturing processes are shown in italics.)

January 2008 REINFORCEDplastics 33

 Feature
Mechanical Properties
Material Price
Injection
Moulding
Reinforcement
0
Figure 2: Mechanical properties of long fibre thermoplastic materials.
120
100
Annual tonnage (1000 to)
80
60
40
20
0
1982 1984
Figure 3: Market demand for long fibre thermoplastic materials in Europe.
nomenclature for the multitude of semi-
finished products and processing methods
(Figure 1) and the fixing of standard
evaluation criteria and testing yardsticks.
Fundamental work on these topics is being
carried out by the European Alliance for
Thermoplastic Composites (EATC).
The combination of high volume process-
ing and high end-use properties and lower
system costs, is a strong driving force for
further applications. Furthermore, the high
integration potential of LFT – the consolida-
tion of various parts into one single compo-
nent – is rapidly being recognised as a major
advantage in comparison to traditional mate-
rials, and there has been a rapid and steady
34 REINFORCEDplastics
25%. In the past, the tendency was to use
Unidirectional GMT for more simple applications such
as covers and backings or for parts in
Pre
Press unexposed areas, but with the arrival of new
Moulding GMT material systems optimised for the
specific application, and with the ongoing
LFT: lm > 2 mm
Fabric development of the processing and process
engineering, it has now become possible to
mass produce highly stressed structural parts
Mat and innovative module systems with a high
Long Fibre level of functional integration.
Short Fibre GMT is a board-shaped, semi-finished
sheet, typically 3.7 mm thick, in which long
(>12.5-100 mm) or endless glass fibres are
arranged in random form in a thermoplastic
10 100 1000 10000 Quasi ∞ matrix (Figure 4). The usual fibre content
amounts to 15-40% of the weight.
Relative Fibre Length Two processes for manufacturing the
semi-finished sheets have established them-
selves on the market. The moulding impreg-
nation in double band presses (Quadrant
Plastics, Azdel; Figure 5) and the so-called
wet processing or powder processing (Azdel).
The specifically dimensioned pre-cut GMT
LFT (total)
sheets are further processed on a GMT pro-
D- LFT duction line (Figure 6) consisting of a control
LFG system and the following components:
GMT
• tray for semi-finished products;
• oven;
• feeding unit;
• press with tools;
1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 2006 2008
• removal robot; and
Growth of total LFT Market in the last 10 years: 8 - 15%
• (optional) punching and deflashing unit.
Transfer between the different units can be
growth in the use of long fibre reinforced carried out manually or, as in most cases,
plastics in recent years (Figure 3). fully automated by robots. The GMT pre-
cut sheets are taken by a vacuum grabber
from the magazines and put onto the oven
GMT
conveyor belt. The semi-finished sheets must
For a long time, the main driving force for be heated to melting temperature before
new thermoplastic composite developments processing outside the tool.
and series applications, was represented There are different oven systems on the
by the group of glass mat thermoplastics market: convection type heaters; radiation
(GMT), which were developed in the USA by heaters; and contact heaters. Each has its pros
PPG/Union Carbide under the brand name and cons. For production lines, usually feed
Azdel, at the end of the '60s. The development or paternoster ovens are used ie. the GMT
history of GMT is outlined in Table 2. semi-finished part is driven into the oven by
After market launch of GMT in Europe a grid belt or a transport system. For trials or
in 1982, a rapid period of growth began, laboratory situations, simple one-step oven
with annual rates of growth amounting to systems can be used.
January 2008
 Feature
GMT structural parts can be used in
combination with conventional materials
like metals due to their excellent stiffness/
weight ratio combined with good crash
properties, high energy absorption capability
and high expansion. Current examples of
applications in the automotive industry
include instrument panel supports, technical
front-ends, door modules, bumper supports,
sound-absorbing shells, spare wheel pans
and – one of the fastest growing applications
– complete underbody systems. Only 2% of
the GMT produced is used outside of the
automotive industry.
Only 2% of the GMT
produced is used outside of
the automotive industry.
Current trends in GMT materials
1. Partially consolidated GMT systems for
lightweight constructions
Growing market demands for materials for
thin-walled structural parts like underbody
systems and for structural support materials for
so-called direct laminate or one-shot processes
led to the development of a number of partially
consolidated GMT systems. These are called
lightweight reinforced thermoplastics (LWRT)
as they are produced at values of down to 1200
g/m2 as opposed to alternative LFT production
methods like extrusion or injection moulding,
where minimum substances of 2000-2500 g/
m2 are used.
Quadrant's SymaLite® is a composite
fibre mat consisting of glass fibres and
thermoplastic fibres, and is produced in a
special carding system. Azdel's corresponding
product, SuperLite®, is manufactured on the
basis of existing papermaking technology by
partially extracting the internal propellant.
These materials can be partially compressed,
so extensive structural parts with extreme
differences in thickness can be realised.
Current applications are the underbody
systems of the BMW 5 and 6 series.
LWRT manufacturing methods can
also be used for a wide range of alterna-
tive reinforcing fibres (aramid, carbon) or
36 REINFORCEDplastics January 2008
Polypropylene
Glass Fibre Mat
Polypropylene
Glass Fibre Mat
Polypropylene
Nomenclature: PP- GM 30
Matrix: PP
Reinforced Glass Mat
FFibre Volume 30%
Figure 4: Structure of glass mat thermoplastics (GMT).
Extruder
Dosing Unit
Granulate, Additive
Overlay-Roll
Glass Fibre Mat
Figure 5: Manufacture of GMT by the extrusion process.
natural fibres (sisal, flax, hemp etc). The
use of spun matrix filament also enables
the application of alternative matrix poly-
mers (PA, PET, PBT etc) with higher heat
stability. The use of highest temperature
stable, intrinsically fire resisting or smoke
gas free thermoplastic systems (PEI, PEKK
etc) is quite feasible for applications such
as extensive, self-supporting interior panels
in buses, trucks, trains and planes. With
low pressure compression moulding (<5
bar specific melt pressure) being suitable
for these systems, extensive structural parts
like roofliners can be laminated directly,
ie. in one production step, with textiles or
foils. Direct back-pressing of fragile foam
foils is possible without the foam collaps-
GMT- Semi-finished
product
- Compressing
- Moulding
PP- GM 30 UD 20
Matrix: PP
Reinforced Glass Mat
30 %
Unidirectional roving 20 %
Double Band Press Cutting Unit
Heating Cooling
Semi-finished
product
Component Specific
Semi-finished Sheet (d=3.7 mm)
ing. Low work pressure enables the use of
inexpensive tools – aluminium (series),
plastic, wood (prototypes).
2. GMT with directed long fibre
reinforcement for structural applications
An interesting and trend-setting develop-
ment is the so-called 'Advanced GMT', which
combines the advantages of conventional
GMT processing of random mats or con-
tinuous fibre mats with the high mechanical
potential of directed fabrics or unidirectional
(UD) layers.
In the production of the GMT semi-
finished products in the double-band
moulding press, the fabrics or UD layers
are put in different positions or layers
continuously or discontinuously. The

positioning depends on the mechanical
demands and clearly influences the features
of the semi-finished product. The number
and position of the fabrics or UD layers can
be chosen in any combination which leads
to customised solutions for process ability,
features and cost-effectiveness.
Advanced GMT parts are produced, like
GMT, by compression moulding with flow.
The fabric remains in the original position of
the blank when it is extruded. It can re-shape,
but it cannot flow.
The random oriented fibres in the needled
mats have a considerably higher flexibility
and are homogeneously distributed over the
complete volume of the structural parts as a
result of the high hydrodynamic flow. Usually,
the reinforced cuts are combined with other
GMT cuts so that there are enough free-flow-
ing random fibres to fill the complete volume
of the structural part. Cost-effective mass
production of heavy-duty structural parts
with high processability can be realised with
the use of a local reinforcement of Advanced
GMT. No additional handling or production
step is necessary here, as it is in mounting or
hybrid methods, where pre-consolidated ele-
ments and units are used.
The first advanced GMT types have been
used since 1998 for heavy-duty underbody
skid-plates or for bumper beams and have
proved themselves well. Since then Advanced
GMT has widened its serial application to
spare wheel pans, rear axle supports and rear
doors. These parts have the following in com-
mon: complex geometry; good crash features
due to high energy absorption and ductile
fracture behaviour; and high stiffness/weight
ratio.
Long fibre reinforced granulates
The pioneering influence and driving force
behind the new developments in LFT and the
introduction of large-volume applications
have been the GMTs. Although the GMT
process is an established and well known
technology, its role of a 'trailblazer' for
new and innovative applications is being
challenged. As a result of the necessity of
massive cost savings – a clear demand,
especially from the automotive industry
Control
Oven
Figure 6: GMT processing line.
– a number of alternative materials and
processes have been developed in the last
few years.
Long fibre reinforced granulates (LFG),
pellets and chips, prepared by wirecoating,
crosshead extrusion or several pultrusion
techniques were introduced 12 years
ago; recent developments are based on
commingling and powder impregnation
techniques. These long fibre granulates
are suitable for both the classic injection
moulding process (IM) and the injection
compression moulding process (ICM) as well
as for the extrusion compression moulding
process (ECM).
Common to all these processes is a
plastification unit in the form of an injection
or extrusion screw, which is the mainspring
for the process intrinsic deficit – an apparent
fibre length degradation in the finished part.
The degradation is caused by the friction,
shearing and orientation steps which have
an effect on the necessary melting and
processing temperatures in the plastification
of thermoplastic matrices (ie. on the glass
filaments) as well as by the interaction of the
glass fibres.
This typical reduction of the fibre length
is irrespective of massive ameliorations in
the field of the plastification systems (screw
geometries, mixing zones etc) and optimised
process parameters (screw speed, injection
speed, back pressure etc).
Feature
Post-processing
Hydraulic
press
As one example, the degradation of the
average fibre length of an LFG with 25 mm
initial length in the extruder zones of the
plastification extruder down to 4 mm in
the finished part was shown. The values
given were gained from samples which were
taken from a plastification extruder, from
the plastificate and the pressed part. These
samples were incinerated and then evaluated
in microscopic picture processing.
Specifically in closed mould operations
– as in the classic injection moulding process
– the additional fibre length reduction in the
nozzle, the grating system and the mould
itself (such as geometry and radii) must
be taken into consideration to minimise
fibre breaking and non-uniform physical
properties in the finished part. It has been
shown that considerable fibre lengths
in the finished parts can be realised with
the injection moulding process when the
machines are adapted to the properties of the
LFGs and the tools are shaped accordingly.
Here the degradation of the LFG of original
15 mm fibre length down to an average fibre
length of 2.85 mm in the finished part was
shown.
Very often, this degradation is only seen
in the context of reduced mechanical proper-
ties, especially in reduced impact resistance.
Significantly more important, however, is
the fact that shrinkage and distortion, espe-
cially in extensive, pan-like moulded parts
January 2008 REINFORCEDplastics 37
 Feature

of low design stiffness, affect the quality and

useability in the subsequent finishing and
mounting process.

LFT direct processes

A real breakthrough in thermoplastic com-
posites was, at the beginning of the 1990s,
the idea of combining the compounding of a
long fibre reinforced thermoplastic material
directly with the final part production proc-
ess. The reinforcing fibres were incorporated
and impregnated with the polypropylene
matrix directly during the compounding
and plastication process of the thermoplastic
composites (D-LFT process).
The main developments were performed
in the area of extrusion compression
moulding. These process technologies could
be differentitated by different compounding
methods (single or double screw extruder),
impregnation methods (direct feeding ro
accessory systems), reinforcing material basis
(chopped or endless fibres), matrix material
(PP in form of granulates, powder or water
dispersion). Although the development of
modified injection moulding processes was
started almost 15 years ago, a broad industrial
introduction of these systems only started in
2001. In the past five years, the direct processes
have achieved a significant market share.

The cutting out of the

semi-finished material
step also has some
drawbacks.
What are the consequences of this for the
processing industry?
The leaving out of semi-finished products
leads to a clear benefit concerning to the
material and process costs. Another benefit
is the additional heating and plastification
process of the matrix is left out, so the
thermal stress as well process stabilisors are
reduced. Furthermore, the part producer
can vary the process conditions and material
recipes on a wide scale and can adapt the
process quickly and efficiently according to
the needs of the specific part. Some examples of commercial LFT applications.

38 REINFORCEDplastics January 2008


But the cutting out of the semi-finished
material step also has some drawbacks – the
part producer is not only responsible for
the final production but additionally for
the homogenisation and preparation of the
raw materials and the material classification
and quality. Furthermore is has to be noted
that an in-line compounding system needs
higher investment costs and skilled service
personnel. The investment costs for in-line
compounding systems are clearly higher than
the costs for a conventional plant.
Regarding all these developments in the
field of new materials and different processes,
the part producer is confronted with the
question of which kind of process and which
kind of material is the right decision. On the
one hand he has to fulfill the demands and
requirements of his customer for a specific
part; on the other hand he has to produce on
a cost level which is accepted by the market.
New models are introduced ever faster,
development time is reduced, yet the plant
should be loaded to full capacity and written
off in time. Even if all the technical and
economical aspects are taken into account,
the right decision is difficult.
One of the main tasks in future projects
will be the qualified comparison of different
types of materials in one and the same appli-
cation, the assessment of different processes
and the efficiency of process parameters.
Therefore a basic understanding of the gen-
eral influencing factors by the designers and
the engineers is a very important condition
for a better understanding of the perform-
ance, the advantages and the limitations of
long fibre reinforced thermoplastics.
Future developments
The high cost pressure will lead to the
replacement of the processes based on
semi-finished products, GMT and LFG, by
direct processes (D-LFT). The still existing
advantage of the GMT materials is being
caught up by the development of well adapted
material and processing technologies. Still, the
undeniable advantage of the GMT systems,
the combination of high impact resistance
and at the same time high stiffness, will
hardly be reached by alternative materials
Table 3: The advantages and disadvantages of the LFT processes with closed
machines and the processes with open machines
Compression moulding (CM) and injection
compression moulding (ICM)
- flashes (post-processing)
- stamping/milling (f. breaches)
+ shorter cycle time
+ higher fibre lengths
+ mechanical properties
high toughness (εB, impact resistance)
high damage resistance
and processes, especially in the hybrid
GMT systems with directed reinforcement.
Significant progress has been described in
this area. For the LFG part producer, in-line
blending was developed as an alternative to
the direct LFT processing. In this method,
LFG concentrates with a high fibre content
are used (with glass content of up to 75%)
and mixed with (un-reinforced) PP directly
during the manufacturing process in order
to reduce the glass fibre content to the ususal
percentage.
The question of which of the LFT
materials and processes described above will
prevail on the market cannot be answered
in general, as the decision always depends
on the parts produced and their specific
parameters. In a comparative evaluation, the
advantages and disadvantages of the LFT
processes with closed machines (injection
moulding) and the processes with open
machines (compression moulding or
injection compression moulding) can be
comprised (Table 3).
The process-intrinsic advantages of the
direct methods, which use a combination of
compression moulding and closed machines,
predict a high market share for those methods.
The economical benefit of producing flash-
free parts with little post-processing and
better surface quality will in many cases
prevail over the technological drawback of
a lower mechanical performance due to the
higher fibre length degradation.
The combination of the D-LFT ECM
process with local endless fibre reinforcements
Feature
Injection moulding (IM)
+ contour accuracy parts (flash free)
+ integration of inserts
+ better surface quality
+ potential of approved special
technologies (eg. multicomponent-/gas
injection-IM)
- longer cycle time
- higher fibre length degradation
- mechanical properties
and fabric reinforcements, which are heated
outside the mould and then fed into the
mould together with the plastificate, leads
to a significant improvement of the impact
resistance and crash properties. Also the
combination of the D-LFT process with
pre-processed reinforcement inserts in
the extrusion compression moulding and
injection moulding process, is indeed possible
and already being realised successfully.
Significantly reducing the weight of
vehicles is mandatory for ecological and
economical reasons. The trend towards
customer-segment vehicles and small-series
vehicles with short market cycle times is
remaining. Cost optimisation is increasingly
important. Thus, the use of structural parts
made of thermoplastic FRP in the automotive
industry will increase. ■
Prof. Dr.-Ing. Michael Schemme,
University of Applied Sciences,
Hochschulstraße 1, 83024 Rosenheim,
Germany; e-mail: schemme@fh-rosenheim.
de; www.fh-rosenheim.de
This article was presented at the 10th
International AVK Conference on 5-6
November 2007 in Stuttgart, Germany. The
11th International AVK Conference will be
held on 22-23 September 2008 in Essen,
Germany, alongside Composites Europe
2008.
AVK; www.avk-tv.de
Composites Europe; www.composites-
europe.com
January 2008 REINFORCEDplastics 39