Material Solutions for Commercial Vehicles

Material Solutions for

Commercial Vehicles

© 2014 Celanese CEM-027 AM 04/14

Material Solutions for Commercial Vehicles 1

Structural Parts



Celstran ® LFRT

► Better scratch and mar compared to talc PP

► Optimal mechanical performance

► Improved creep resistance

► Improved impact performance

► Improved notched impact strength

► Superior tensile strength

► Greater load bearing capacity

► Increased sound dampening properties

► Low carbon emission

► Energy efficiency in processing


Best Cost-to-Performance Ratio



Physical Property Overview

Celstran PP-GF40-20

Specific

Gravity

Tensile

Strength

Elongation

Tensile

Modulus

Flexural

Strength

Flexural

Modulus

MPa % GPa MPa GPa

Notched

Charpy

Impact kJ/m 2

145 Celstran PP-GF20-02 1.03

Celstran PP-GF20-0553 1.03



1.21

88

80

98

107

150

2.8

2.4

2.2

2.6

2.1

4.60

4.60

6.35

6.20

10.00

162

164

200

4.63

4.70

6.40

6.05

8.70

19

18

23

38

35

Grade Suffix

-02 - General Purpose

-03 - Heat Stabilized

-20 - High Performance

-0553 - High Impact, Low Odor, Low VOC

© 2014 Celanese CEM-027 AM 04/14 Material Solutions for Commercial Vehicles 4

Celstran ® LFRT vs. Short Glass PA66

1,800,000

1,600,000

1,400,000

1,200,000

1,000,000

800,000

600,000

400,000

200,000

0

43% SF PA66 33% SF PA66 PP-GF40-02 PP-GF40-09 PP-GF40-10


Temperature °C


Celstran ® LFRT GF30-05 vs.

PC-ABS and SMA

100

90

80

70

60

50

40

30

20

10

0

0

SMA GF16

Pulse 630GF

Celstran PP-GF30-05

Yield point > 2.5% toughness area

SMA with brittle breakage

0,5 1,0 1,5 2,0

Elongation

2,5

Source: Kunststoffe 3/2003


Superior Toughness Behavior

Material Solutions for Commercial Vehicles

3,0 3,5

6


Advantages vs. SMA and PC-ABS

► Weight and cost savings

► Optimal mechanical performance

► Improved creep resistance

► Improved impact performance

► Improved notched impact strength

► Superior tensile strength




► Energy efficiency in processing


Best Cost-to-Performance Ratio


Celstran ® LFRT for IP Applications

Celstran+ PP-GF20 Celstran+ PP-GF30 Celstran+ PP-GF40

GF20 Blend

(Concentrate Technology)

GF30-04CN02/10

GF30-05CN01/10

Concentrate Technology*

GF40-04CN10/10

Instrument Panels

Air Duct Panel

Assembly Parts

Concentrate Technology

40-60% reinforcement available

► PP-GF40-04CN15/10

(concentrate to let-down to GF20)

► PP-GF45-05X551-1X


Fan Housings

Housings

Integration

Instrument Panels

P-Airbag Chute

Channel

Assembly Parts

*Optional: Concentrate

Technology 45-60% reinforcement available

► PP-GF45-05X551-1X


► PP (+) GF60-04


Fan Housings

Structural Parts

Front End Modules

Pedals

Housings

E-Box etc.

Grades to Meet Application Requirements



What’s the Limit?

► Molded-in-color LFRT versus current talc-PP production

► 20% glass filled, achieved by blending natural PP with a

40% GF grade

► No loose fibers visible on surface

► Improved 60-deg. gloss

(2.9 drops to 1.8 in same tooling)

► Significantly greater stiffness

► Lower VOCs for cleaner cabin environment



Bumper Support

Features and Benefits

► Improved stiffness and strength vs. competitive materials

► Allows for thinner wall design

‒ Lower weight

‒ Less material usage over the life of the program

Console Bin


Outer console



Side Fairings


► Impact resistance

► Creep resistance

► Dimensional stability

► Ability to withstand paint oven temperature

Passenger Side

Outer console – PP molded in color

Driver Side



Battery Box


► Stiffness

► Excellent impact

► Excellent chemical resistance

► UV stabilized

► Improved aesthetics



Shifter Base


► Reduction of squeak and rattle TGWs for final assembly

► Best cost-to-performance ratio vs. SMA and PC-ABS

► Exceptional impact at low and high temperatures





Powertrain



Fortron ® PPS Competitive Comparisons

Fortron ® PPS Versus Other Thermoplastics (PAI, PEI, PES)

► Superior resistance to fossil and biofuel blends, coolants, brake/transmission fluids

► High flow enables more complex part geometries

► Greater design flexibility; higher precision parts possible

► Consistent molding of thin-walled, intricate parts, typically with faster molding cycles, yielding higher productivity


Fortron ® PPS Expands Metal / Thermoset

Replacement Opportunities

Criteria Fortron ® PPS

Cost of Raw Material Higher

Processing Easier and faster

Phenolic

Lower

Slower

Finishing Operations

Recyclability

Surface Finish

None required

Easily recyclable and regrind reusable

Excellent

Requires secondary operations

Difficult to recycle and can’t use regrind

Excellent

Impact Strength

Design Flexibility

High-Temperature

Properties

Specific Gravity

Finished Part Cost

Higher

Flexible

Excellent

Lower

Lower

Lower

Inflexible

Annealing required

Higher

Higher

Die-cast Metal

Lower

Slower

Machining

Can’t regrind

Machine surface

Higher

Inflexible

Excellent

Higher

Higher


Fortron ® PPS

Comparison With Other Materials

Relative Strength Comparison

Material

Fortron (40% Glass-Reinforced)

Fortron (53% Glass/Min-Reinforced)

Nylon 6/6 (33% Glass-Reinforced)

7-18

18-27

Aluminum

Zinc

Bronze

Brass

18-27

14-20

Relative Stiffness Comparison

Material

Tensile Yield

Strength (KPsi)

25

21

8.5

7-18

18-27

30-38

1.9

2.7

6.7

8.7

8.8

18-27

14-20

Fortron (40% Glass-Reinforced)

Fortron (53% Glass/Min-Reinforced)

Nylon 6/6 (33% Glass-Reinforced)

Phenolic (Hi-Strength Glass-Reinforced)

Aluminum

Zinc

Bronze

Brass


Modulus

(10 6 psi)

1.9

2.1

0.9

2.0

10.0

12.0

13.0

12.0

Material Solutions for Commercial Vehicles

Specific

Gravity

1.6

1.8

1.4

1.9

2.7

6.7

8.7

8.8

Strength/Weight Ratio

(Normalized %)

100

75

39

24-61

43-64

29-36

24-61

43-64

29-36

13-20

10-15

13-20

10-15

Strength/Weight Ratio

(Normalized %)

100

94

54

89

311

151

126

115

17

Fortron ® PPS

Additional Comparisons

Customer Benefits:

Fortron ® PPS vs. Metals

► Reduced waste and disposal problems, less environmental impact

► Inherent corrosion resistance

► Reduced part weight due to lower density (e.g., shipping costs)

► Elimination/reduction of finishing steps; enhanced design freedom, reduced assembly time, part consolidation

Fortron ® PPS Features

► Regrindable; recyclable

► Much lower density, e.g., 1.65 g/cm 3 vs. 2.7 – 7.0 g/cm 3 for metals

► Excellent chemical/fuel resistance

► Superior “as molded” surface finish


Fortron ® PPS for Powertrain

Typical Applications

► Fuel systems (delivery modules, pumps, fuel rails, injectors)

► Engine cooling (pump impellers, stators, rotors, crossovers)

► Engine and transmission thermostat housings

► Brake systems and transmission accumulator pistons

► Turbocharger ducts, charge air coolers and actuator gears

► E/E components (sensors, connectors, control modules, bobbins)

► Ignition stick coils and coil-on-plugs

► Throttle bodies and plates

► EGR diverter valves, heat exchanger components, ducts, gears, bushings

► Power steering gears and hose assemblies

► Fiber reinforced coolant hoses


Fortron ® PPS

Electric Water Pump

Requirements

► Resistance against water-glycol agent mix up to 140°C

► Internal pressure up to 3 bar

► High heat resistance also under high mechanical load

► Tight tolerances for rotor bearing

► Good flow-properties for wall thicknesses down to 0.5 mm

Electric Water Coolant Pump

Fortron ® 1140L6 / 6165A6

Fortron 6165A6

Fortron 1140L4

Ferrit-filled PPS

Fortron 6165A6


Fortron ® PPS E/E Applications

Sensors, Actuators, ECUs, Bobbins


► Exceeds under-the-hood temperatures of 150°C with UL continuous use temperatures up to 240°C

► Excellent dimensional stability and creep resistance

► Heat shock resistance, -40°C to 170°C

► Good dielectric properties

► Ability to mold thin walls with low mold shrinkage and low differential shrinkage (i.e., excellent flatness)


Bobbins – Fortron ® PPS


Fortron ® PPS

Drivetrain Systems


► PTFE seal overmolded with Fortron PPS

► Excellent chemical resistance to fossil and biofuel blends and petroleum oil products

► Low creep at high temperatures

(short-term peaks up to 170°C)

► Excellent dimensional stability


Engine Crankshaft Seal – Fortron ® 4332L6


Fortron ® PPS

Turbocharger Systems


► Replace aluminum

► Dimensional stability at elevated temperature

► Pressure pulsation tests at 220°C over 500,000 cycles

(overpressure max. 2.1 bar)

► Chemical resistance to automotive fuels and fluids

► Sufficient toughness for crimping process weight : 2800g

Charge Air Cooler Tank – Celstran ® PPS GF40


Fortron ® PPS

Turbocharger Systems

Duct Requirements (Fortron ® 1115L0)

► Weight reduction (30% weight savings vs. aluminum)

► Temperature resistance up to 230°C

► Weldable with all standard methods

► Excellent chemical resistance to automotive fuels and fluids

Bracket Requirements

(Fortron ® FX4330T7)

► Low viscosity

► Impact modified grade

► High toughness

► Perfect adhesion to pipe

Blow Molded Charge Air Duct

Fortron ® 1115L0

Fortron ® FX4330T7


Fortron ® PPS

Greater Rigidity Over Non-PPS Polymers

► Over time and equivalent loads, Fortron ® PPS remains stiffer than Nylon

4/6 and PPA at elevated temperatures

► Designers will need to use more material (i.e., thicker walls) to increase the stiffness of parts made from competing nylons

Flexural Creep Modulus 250 °F, 4350 psi, 1000 hours

Fortron ® 6165A4

Fortron ® 4184L4

30% glass, HS, N46

40% glass, Fortron 1140L4

45% glass, HS, PPA

65% min/glass, HS, PPA

33% glass, HS, PPA

40% mineral, PPA

0 200 400

Kpsi

600 800

Fortron ® PPS – Stiffness at Elevated Temperatures

1000


Polymers for Low-Emission

Diesel Vehicles

Fortron ® PPS


Celanex ® PBT

► Superior chemical resistance

► No measurable contamination of the AdBlue

► Suitable for direct contact with

AdBlue

► Applications include pumps, valves, sensors and timing cases

Note: AdBlue is registered trademark of Verband der Automobilindustrie

Provides Long-term Performance in Contact with AdBlue ®


Interior



Interior Trim Applications and

Requirements

Tribologically treated components

► Sun visor

► Cable guidance

►

Gears and gear systems and housings

Metal substitution

► Door handles

► Door bezels

Functional parts

► Clips and fasteners

Structural parts

►

Sun visor

►

Requirement

►

Low friction & wear

►

►

►

High stiffness/strength

High HDT

Low warpage

►

Low moisture abs.

► Low friction and wear

► High stiffness

►

UV-stability

►

Low warpage

► High stiffness/strength

► High HDT

►

►

Material

Hostaform ® POM

► Celanex ® PBT

► Celstran ® LFRT

► Hostaform POM

►

Hostaform ® POM

► Celstran ® LFRT

►

Celanex ® PBT

►

Celstran ® LFRT

► Hostaform POM



Combining Structure and Appearance

► Reduction of extra aesthetic trim parts or paint

► Flexibility to design thinner wall structures (10 – 15%)

► First surface class ‘A’ interior combined with structural integrity

‒ Textured surface

‒ Molded in color technology


Celstran ® LFRT for Appearance

Scratch and Mar

Celstran LFRT 20% vs. Talc-PP

(Ford A10 material)

Head-to-Head Testing Conducted

► System: Ford Focus

► Part submitted: O/H Console Door

► Tested by: Detroit Testing Laboratory, Inc.

► Test standards: Ford standards

► Result: No visible whitening


No Visible Whitening or Marring



Overhead Console

► Unique use of injection-molded long-glass fiber-PP materials

‒ Above-the-beltline

‒ Class A interior part

‒ Light texturing and in light colors

‒ Replaced a talc-filled TPO material that had insufficient thermal stability

► Superior scratch and mar resistance

► Improved strength, HDT and stiffness

(less warpage under heat)

► Low gloss

► Special UV-protection package helps stabilize the colorant

► Components sonically welded to the bin door

► Improved craftsmanship and appearance come at a slight cost reduction as well



HVAC Vanes

The Challenge:

► High modulus in very thin sections

► “Robust feel”

► Good surface finish

GM – Corvette

The Innovation:

► High modulus in thin

1.84 mm cross section

► Class “A”, molded in color, without secondary finishing

Nissan – Quest Cadillac – STS



Door Scuff Plate


► Class A interior part


► Improved strength, HDT and stiffness (less warpage under heat)

► Enabled a simpler design

► Eliminated two attachment clips (from 5 attachment points to 3)

‒ Reduced installation cost

‒ Reduced material costs

33 © 2014 Celanese CEM-027 AM 04/14 Material Solutions for Commercial Vehicles


Center Console Side Panels


► Class A surface out of the tool (used on a premium vehicle)


► Low gloss and wide range of color capability

► UV stabilized

► Precolored and textured part

‒ 100% color-matched

‒ No glass read-through

‒ Offers higher stiffness than talc-filled

PP (by 65%)

‒ Lower cost than ABS (~ 20%)

‒ Eliminated the need for squeak and rattle countermeasures



Sunshade Cassette


► 14% weight savings vs. previous design


► Allows part consolidation through a simpler design

► Structural capability with appearance

‒ Class A interior surface

‒ Improved strength, HDT and stiffness

‒ Low gloss and wide range of color capability

‒ UV stabilized

First Surface Appearance and Weight Reduction



Commercial Vehicle Gear Shift Lever


► Manufactured using gas assist technology

► Low warpage

► Good surface finish

► Weight and cost reduction vs.

PA66 SG35

This Appearance Can also be Achieved in Combination with Gas Assist Molding


Hostaform ® and Celcon ® POM

Structure and Characteristics

► Hostaform ® and Celcon ® POM Acetal Copolymer:

‒ Linear structure and high crystallinity

‒ Inherent high stability vs. thermal and oxidative degradation

(vs. homopolymers)

Attributes of Hostaform ® and Celcon ® POM

►

►

Broad operating temperature (-40°C - 100°C )

Good dimensional stability – low moisture absorption

► Excellent fatigue and creep resistance

► Excellent tribology behavior

‒ Low friction and wear resistant properties

► Good chemical resistance

‒ Fuels, solvents, strong alkalis

‒ Resistant to environmental stress cracking

► Easy to process


Hostaform ® POM

Cabin Environment

Hostaform ® Next Generation XAP

2™

Advantage of Low Emission XAP ® Grades

► Hostaform ® XAP 2 products will offer at least 50% improvement versus first generation XAP ® products

‒ Significant reduction in emission confirmed by customers

‒ Fulfilling future automotive OEM’s requirements <5 ppm

‒ Hostaform ® /Celcon ® XAP 2 products will offer inherent

‒ Process robustness – no mold deposit

‒ Mechanical and chemical properties

‒ Impact resistance and resilience

‒ Excellent slip and wear characteristics

‒ Broad range of Hostaform ®

/

Celcon

®

XAP

2

grades available

Reduces VOC Emissions for Automotive Interiors


Hostaform ® POM Appearance Series

MetaLX ™ MIC (Molded In Color)

► MetaLX

™

MIC technology can be used with POM, PBT,

TPC-ET and LCP

► Eliminate associated costs with painting and plating

► Reduction in secondary processing steps

100% ► Eco-friendly vs. painting and plating

► Potential cost savings realized for customer

► Custom color matching available

‒ Colors meet automotive UV requirements

80%

60%

40%

20%

8

Different

Manufacturing

Processes

(Including

Painting)

Minimum

4 Operators

MetaLX TM POM

Potential Savings

1 Manufacturing

Process

(Injection Molding)

1 Operator

0%

Painted/Plated Unit

Cost/Part

Raw Material

Additional Parts

MetaLX

™

Unit Cost

Manufacturing

Assembly

Hidden Costs in Paint and Plating Make

MetaLX™ an Attractive Alternative Solution


Hostaform ® MetaLX™ POM

Steering Wheel Bezels


► Eliminates

‒ Painting/top coating and related secondary costs

‒ Paint waste/volatile organic chemicals

‒

Painter part scrap and associated environmental impact fees

‒ Special packaging and shipping

► Resistance to stains, scratches, wear (durability) and most chemicals and cleaners

► Color matching to interior painted or metallic colors

► UV resistance

Achieve Metallic Look for Trim Parts without Painting or Plating


Hostaform ® POM Appearance Series

Laser Marking


► Indelible image on low gloss and high gloss surfaces

► Excellent contrast in white or colored characters

► No pre-treatment required

► Practical solution to existing marking methods

– Printing, labeling, others

► Flexible – contactless marking system

‒ Fast and reliable

‒

Excellent shot to shot consistency

– even complex 3D parts

‒ Tamperproof – traceability ensured

‒ Excellent contrast – sharp indelible images

Demo Plaque

LM90 CF2008

Cost Effective Mono-Layer Solution to Marking of Thermoplastics


Hostaform ® and Celcon ® POM

Innovative Hybrid Platform Overview

Standard

Unfilled

Low

Permeation

Impact

Modified and Extreme

Toughened

Glass

Reinforced

Flexible

Improved

Resistance

(Weather,

Media, UV)

Medical

Technology

Appearance

MetaLX

™

and

Low Gloss

Electro

Conductive

Low Emission

Tribology

Low

Warp

Portfolio Designed by Application Demands


Hostaform ® POM S and XT Series

Overview

New POM (Hybrid) Backbone Technology Offering a Unique Solution:

► Improves coupling strength to impact modifiers – enhancing mechanics

► Attributes: Hostaform ® Impact Modified (IM) Series vs. Conventional (IM)

Products

‒

Improved toughness-to-strength ratio and creep resistance characteristics

‒

Superior weld line integrity

– broaden design freedom

Conventional (IM) POM Cross-section of weldline New Hybrid Technology Superior Performance

Competitive

Homopolymer impact modified

Celanese Internal Testing @ 23 ° C

Hostaform ®

S 9364

25 µm

New Hybrid (IM) S and XT Series Cross-section of weldline

Competitive

Copolymer impact modified

25 µm

New Hybrid Technology Delivering Superior Performance


Hostaform ® POM S and XT Series

Summary

► S (high impact) and XT (extreme toughened) series

‒ Greater design freedom / Improved weld line strength

‒ Broad portfolio / Right product for application performance

► Superior Mechanical Performance vs. Competitive IM-POM copolymers

‒ Superior thermal stability vs. (IM) homopolymers

‒ Challenge out-of-kind (IM) - PAs and TPU resins

‒ Similar mechanicals and dimensional stability

Door

Systems

Gear

Systems

Fastener

Systems

Door and Window

Systems

Safety

Systems

Straps and Buckles Door Lock

Components

Clips and

Fasteners

Window

Lift Systems

Retractor Plates and Pillar Loops

S and XT Series Challenging New Application Space for POM Solutions


Hostaform ® XGC Series

Overview

New Product / Unique Solution

► Developed new POM (Hybrid) technology

‒ New technology improves coupling strength to glass fiber

‒ Improved mechanicals vs. conventional reinforced POMs

‒ Closes the gap to glass fiber reinforced polyesters, PA6 and PA66

Current XGC (Extreme Glass Coupled) Series

‒ XGC10, 10% short glass coupled

‒ XGC25, 25% short glass coupled

‒ XGC15 LW-01, 15% short glass coupled – Tribology modified grade

‒ XGC25 LW-01, 25% short glass coupled – Tribology modified grade


Hostaform ® XGC POM Series

Benefits of XGC vs. Various NBAs

Property

Physical

Properties

Process

Applications

Emissions

Shrinkage

Temperature

Characteristics

Stiffness / Strength

Strain

Toughness

Processing temperatures

Pre-drying requirement

Hot water contact (>60°C)

VDA275

Lower anisotropic behavior

Operating temperature range

+

+

+

+

XGC POM GF PA GF PBT GF

+

0

0

–

–

–

0

+

+

+

–

–

+

+

+

+

–

0

–

–

–

/

–

–

–

–

/

–

0 0 + +

Innovative High-Impact Platform Expands Opportunities


Hostaform ® XGC Series

Summary

Hostaform ® XGC - Advantage vs. Polyesters and PA GF Resins

► Balanced physical properties characteristics

‒ Improvements in stiffness, strength and toughness

‒ Improved mechanicals vs. conventional SGF reinforced POMs

‒ Dimensional stability – humidity and temperature independent

‒ Process (thermal stability) robustness

‒ Low emission VDA275 compatibility (under development)

► Sample material available to support validation programs

47 © 2014 Celanese CEM-027 AM 04/14 Material Solutions for Commercial Vehicles

Technical Services

Engineered Materials



Innovative Technical Polymers and Solutions

Creating Groundbreaking Solutions

Celanese is a trusted global leader in engineered materials. We provide total solutions with advanced proficiency in application, processing and design technologies, using local resources but with a global reach. We collaborate to create groundbreaking solutions. By offering unmatched technical expertise and support to help solve challenges and lead the industry forward, Celanese is the choice to increase the value you deliver for your customers.

Celanese technology, laboratories and technical service teams focus on developing new engineered materials that expand your design space. We can provide the technical data and problem-solving tools to help you optimize the performance of our products for your application. Our experienced staff can work with you to make your concept a reality using advanced finite element techniques and processing expertise to support your production process.


A Complete Package for Value Engineering:

Polymers, Design and Processing Know How

Broad Technical Services

► Intensive project consulting services

► Material selection and feasibility studies

► Component design support

► Design support (CAE, structural analysis, mold filling simulation)

► Product testing tailored to support your applications

► Field support for prototyping and production optimization

► In-house workshops and training


Part and System Development Support

1. Development of ideas

2. Component design and material selection

3. Mold filling simulation, prototyping

4. Tooling recommendation and engineering

5. Material specification testing

6. Component design validation

7. Production verification and support

Valuable Cooperation for Value Engineering

© 2014 Celanese CEM-027 AM 04/14 Material Solutions for Commercial Vehicles

Specification

51

Disclaimer

© 2014 Celanese or its affiliates. All rights reserved.

This publication was printed based on Celanese’s present state of knowledge, and Celanese undertakes no obligation to update it. Because conditions of product use are outside Celanese’s control, Celanese makes no warranties, express or implied, and assumes no liability in connection with any use of this information. Nothing herein is intended as a license to operate under or a recommendation to infringe any patents.

Celanese®, registered C-ball design and all other trademarks herein with ®, TM, SM, unless otherwise noted, are trademarks of Celanese or its affiliates. Fortron is a registered trademark of Fortron Industries LLC.

Contact Information

Americas

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Product Information Service t : +1-800-833-4882 t : +1-859-372-3244

Customer Service t : +1-800-526-4960 t : +1-859-372-3214 e : info-engineeredmaterials-am@celanese.com

Europe

Am Unisys-Park 1, 65843 Sulzbach, Germany

Product Information Service t : +(00)-800-86427-531 t : +49-(0)-69-45009-1011 e : info-engineeredmaterials-eu@celanese.com

Asia

4560 Jinke Road, Zhang Jiang Hi Tech Park

Shanghai 201203 PRC

Customer Service t : +86 21 3861 9266 f : +86 21 3861 9599 e : info-engineeredmaterials-asia@celanese.com


Thank you.

For more information:

1-800-833-4882 info-engineeredmaterials-am@celanese.com

celanese.com/engineered-materials



Material Solutions for Commercial Vehicles

Material Solutions for

Commercial Vehicles

Structural Parts

Powertrain

Interior

Technical Services

Engineered Materials

Polymers, Design and Processing Know How

Thank you.

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