Enabling Vehicle Lightweighting with Advancements in
Surface Treatment and Adhesive Technologies
Presented by:
• Kevin Woock, Global Market Segment Manager – Body-In-White
Adhesive Technologies – Automotive, Henkel
• Dr. Bruce H. Goodreau, Technical Director R&D, Surface Treatment
Platform NA, Henkel
Enabling Vehicle Lightweighting
Kevin Woock
Global Market Segment Manager – Body-In-White
Adhesive Technologies – Automotive, Henkel
Automotive Market Drivers and Focus
Summary: Focus on enabling materials and processes which allow
OEMs and Tier Ones to achieve Body-In-W Weight Reduction
Lightweighting Market Drivers
• Increasing Regulatory Environment
• Cost / Availability of Fuel
• Emerging Market Growth, Urbanization
• Global Platform Development
• Segment Consolidation
• Stamping & Assembly Infrastructure
Targets to Enable
• Product Design (substrates)
– All Steel BIW for A&B Segments
– Steel + Aluminum BIW for C/D/FF
Segments
– All Aluminum/Composites for D/E/Premium
Segments
• Manufacturing (processes)
– Body Shop
• Joining of Dissimilar Materials
• Avoiding Corrosion (Battery Cell w
mixed substrates)
• Safety and durability of new materials
– Paint Shop Oven is pivot point for most
assembly plants
– Post Production – Repair / Recycling (end
of life regulations)
Source: EIGHT REDUCTION IN AUTOMOTIVE DESIGN AND MANUFACTURE ; Published by SupplierBusiness, IHS Automotive, 2012
Convergence of Global Emission and Fuel
Economy Regulations
280
260
240
220
200
180
160
140
120
USA
CAN
EU
AUS
JAP
CHN
17
20
16
20
15
20
14
20
13
20
12
20
11
20
10
20
09
20
08
20
07
20
06
20
05
20
04
20
20
20
03
100
02
CYCLE
GRAMS CO2 PER KILOMETER NORMALIZED TO NEDC TEST
CO2
SKO
Source: The International Council on Clean Transportation, Passenger Vehicle Greenhouse Gas and Fuel Economy Standards: A Global Update2011
Market Research: Global Auto Production
Regional Production Forecast: 2012-2018
120
CAGR (2012-2018) = 4.0%
100
80
60
40
20
0
2012
2013
2014
EU
Source: 2013 March IHS AutoInsight Data
2015
AP
MEA
2016
NA
LA
2017
2018
CAGR
2012-18
EU
2.8%
AP
4.9%
MEA
6.2%
NA
2.3%
LA
5.8%
Total
4.0%
Market Research: Global Auto Production
Shifts in Vehicle Segment Production Volumes: 2012-2018
CY 2012
Volume Variance
CY 2018
A Segment
-0.2%
B Segment
2.4%
30
C Segment
1.3%
D Segment
-1.0%
25
E Segment
-0.6%
FF Segment
-0.8%
Mini FF Segment
0.1%
Compact FF Segment
-1.2%
35
20
15
%of Mix
10
5
0
C
B
Source: 2013 March IHS AutoInsight Data
D
A
FF
E
CFF
MFF
Market Research: Global Auto Production
Global Platforms and Program Consolidation: 2012-2018
“Mega” Platforms over 500K units
per year and number of programs
22
70
18
60
Top 25 Global OEMs 2012-2018
Average Number of Units/Platform
25
19
250
20
50
40
200
12
15
230
150
30
10
100
184
20
30
44
59
48
5
10
50
0
0
2002
2007
2012
2020
0
Units Per Platform (000s)
Platforms over 500K units
Ave. Programs per platform
Source: 2013 March IHS Conference: Successful Global Planning -Detroit
Source: 2013 March IHS AutoInsight Data
Vehicle Lightweighting Trends
• The average vehicle will be 400 pounds lighter by 2025 2
• Average materials content of North American light vehicles
(pound/vehicle)
2009 1
2010 1
2011 1
2025 2
1,501
1,542
1,458
950
High & medium
strength steel
524
559
608
858
Aluminum
324
344
355
550
Plastics/Composites
369
371
377
400
Magnesium
11
11
12
100
Regular steel
1
American Chemistry Council
Worldwide
2 Ducker
Vehicle Lightweighting Trends
Key Material Growth Rates versus Market
Market CAGR Growth Rates 2010-2018
16%
14%
14%
12%
10%
8%
6%
4%
4.2%
2%
0%
Aluminum
Auto Build
Vehicle Lightweighting Trends
Percent of Automotive Material Mix
120%
100%
22%
25%
80%
12%
60%
9%
40%
57%
12%
16%
46%
20%
0%
2012
Steel
Aluminum
2025
Other Metals
Non-Metals
Aluminum in Automotive: SAE World Congress 2012: Contributors : SAE and Aluminum in Transportation Asso.
Vehicle Lightweighting Trends
Aluminum - key focus lightweighting material to 2018
• By 2025, reduce 10 to 20% curb weight or
about 400 lbs.
• Projected to grow to 16% from 9% of curb
weight in period 2012-2025 – increasing some
200 lbs in auto applications
• Key areas for mass reduction include body
structure, powertrain, and chassis components.
• The combination of low density, crash energy
absorption, high conductivity, excellent
recyclability and a good supply infrastructure
make aluminum one of the most desired
lightweight materials in the market.
Aluminum in Automotive: SAE World Congress 2012: Contributors :
SAE and Aluminum in Transportation Asso.
High Growth Al Applications
• Body Panels/Closures
• Wheel Rim/Trim
• Brake Calipers
Moderate Growth Al Applications
• Steering Components
• Tailgate/Rocker Panels
• Suspension arms & knuckles
• Seat frames
Low Growth Al Applications
• Instrument Panel Beams
• Engine blocks, cylinder heads and
crankshafts
• Heat exchanger
Prevalent Substitution Trends with Materials & Chemicals in
Automotive Lightweighting; Frost & Sullivan; June 2011,
M6E0-39
Enabling light weight materials
Adhesives and surface technologies play a central role in
introducing light weight materials
HENKEL TECHNOLOGY
MASS REDUCTION
BONDERITE® pretreatment process
37 Kilograms
LOCTITE® adhesives for multi-material
assemblies
27.4 Kilograms
TEROSON® structural adhesives for the
passenger compartment
14.9 Kilograms
TEROSON® structural inserts
12.5 Kilograms
TEROSON® liquid applied sound deadeners
3.3 Kilograms
TREE EQUIVALENT
Henkel technologies account for nearly 100 kilograms in mass savings for
every vehicle; the environmental equivalent of planting 19 trees
Enabling light weight materials
TEROSON® Structural Adhesives
TEROSON® Epoxies: 5089 – Impact Resistant Structural Epoxy
• TEROSON structural adhesives are highly toughened, structural epoxies
• Adhesives are wash-out resistance and formulated to cure in paint shop process
• Weld-through and multi-metal capable
Benefits
• Provides performance across
the widest temperature range
• Reduces or eliminates welds
• Enables multi-metal design
for structural lightweighting
Application Examples & Value Enhancement
Enabling light weight materials
TEROSON® Aluminum Stress Durable Adhesive
TEROSON® 5100 - Heat Cured Aluminum Stress Durable Adhesive
• TEROSON structural adhesives are a highly toughened structural epoxies
• Wash-out resistance and formulated to cure in typical paint shop process
• New development of stress durability properties on aluminum/multi-metal structures
Benefits
• Reduces or eliminates welds
• Stress distribution allows for
the down gauge of metals
• Enables multi-metal designs
for structure lightweighting
• Allows material and process
design flexibility
Application Examples & Value Enhancement
Enabling light weight materials
TEROSON® NVH and Sealing Solutions
TEROSON® NVH and Sealing
•
•
•
•
Full range of 2 and 3 dimensional parts for NVH and sealing improvements
Complete design competence
Complete DVP&R testing up to full body in white bake out
Materials developed for repeatable expansion over widest application temperatures
Benefits
• Superior acoustic
performance
• Excellent sealing capabilities
• Robust performance
• Assist large product range
for multiple OEM’s and
applications
Application Examples & Value Enhancement
Enabling light weight materials
TEROSON® High Damping Foam
TEROSON® High Damping Foam
• HDF damping properties reduces body shop complexity and manages panel vibrations
•
•
•
and acoustic performance of radiating structures (eg. doors and roofs)
Compatible with current assembly processes and reduces manually applied damping
treatments and anti-flutter mastics
FEA predictive performance validated through testing and analysis
Wash-out resistant material is formulated to expand and bond within the e-coat process
Benefits
• Significant Damping
effect over conventional
materials
• Enables lightweight materials
• Eliminates process waste
• Increases process efficiency
Value Enhancement
Enabling light weight materials
TEROSON® Structural Inserts
TEROSON® Structural Inserts
•
•
•
•
TEROSON structural inserts are designed in 2 and 3 dimensional parts
Used to enhance durability, stiffness, NVH and crashworthiness
Assembled in the body shop or tier manufacturer
Expand and cure in a variety of paint shop processes
Benefits
• Locally reinforce body
structure to avoid lag
• Transparent to existing
processes
• Allow design flexibility
• Assists in weight saving
strategies
Application Examples & Value Enhancement
Enabling light weight materials
BONDERITE® M-ZN 2798 Pretreatment
BONDERITE® M-ZN 2798 Flexible Paint Pretreatment Process
•
•
•
•
Easily integrated into existing paint shop processes
Increased capacity for percent of aluminum substrate, up to 85%
Decrease in sludge generation by as much as two-thirds
Zirconium oxide provides solutions to the limitations a traditional zinc phosphate –
unique deposition on each substrate (no phosphate on aluminum)
Benefits
• Ease of control
• Process cost savings
• Zinc phosphate on CRS, EG,
•
•
HDG, GA
Zirconium based coating on Al
Excellent paint adhesion and
corrosion protection on steel
and aluminum
Application Examples & Value Enhancement
Henkel solutions will help you achieve your
lightweighting priorities
1.
2.
3.
We enable light-weight construction with innovative products and processes.
We contribute to the realization of future CO2 emission targets.
We provide innovative solutions to reduce process costs and to increase product quality.
BONDERITE® Flexible Pretreatment Process for
Multi-metal Bodies with Aluminum
Dr. Bruce H. Goodreau
Technical Director R&D
Surface Treatment Platform NA, Henkel
Agenda
1. Classical Zinc Phosphate Overview
2. Advantages/Challenges of Aluminum Intensive Vehicles
3. BONDERITE® Flex Process
Classical Zinc Phosphate Overview
bulk
solution
M+n
Zn(H2PO4)2
H+
H+
H+
pH increase
2H++eH2
M0
anode
M+n + nee-
Zn3(PO4)2
cathode
Classical Zinc Phosphate Overview
Clearcoat 35-50m
Basecoat 15-40m
Primer 20-50 m
<1 m !
E-coat 20-25m
Zinc 20-25m
Steel
Classical 7-Stage Zinc Phosphate Process
CRS, Zinc and Aluminum
conveyer direction
Clean
Rinse
CRS
Activate
Zinc Phosphate
Rinse
HDG
Post Treatment
Rinse
Al
Classical Zinc Phosphate
Phosphating High Percentages of Aluminum
Challenges
•Aluminum Oxide Layer
• Slows dissolution of Al
• Slows deposition of Zn3(PO4)2
• Dissolved Aluminum
• Inhibits Zn3(PO4)2 deposition on steel
• High levels of fluoride ion
• Safe handling
• Increased Sludge Production
• Na3AlF6
Classical Zinc Phosphate
Al Sludge Production
Increased Al content
1.0g Al
Increased Sludge can result in:
• Increased Maintenance
• Deposition on Horizontal surfaces
• Drag-in to later stages
• Dirt-in-paint
Increased Al sludge
7.8g Na3AlF6 (sludge)
BONDERITE® Flex Process:
Metal Pretreatment for High Aluminum Vehicle Bodies
How do we overcome the challenges associated with
phosphating high Al content automotive bodies?
Don’t phosphate the Aluminum!
BONDERITE® Flex Process Diagram
conveyer direction
Clean
Rinse
Activate
Zinc Phosphate
Rinse
Rinse
Post Treatment
Rinse
Rinse
BONDERITE® M-ZN 2798
Zinc Phosphate
•Reduced Free F- Usage
•Zinc Phosphate on CRS and Zn only
•Phosphate on Al inhibited
BONDERITE® M-PT 54NC
Zirconium Oxide
•Post Rinse for Zinc Phosphate
•ZrO2 Conversion Coating on Aluminum
BONDERITE® Flex Process
Coating Characteristics
Zinc Phosphate on the Steel and Zn substrates only
CRS
CRS
HDG
HDG
ZrO2 coating
Aluminum
Alu
BONDERITE® Flex Process Examples
Zirconium Oxide
Zirconium Oxide on Aluminum
1000x
5000x
BONDERITE® Flex Environmental Benefits
Sludge Reduction
Sludge Reduction with the Flex Process
Process
Al Etch
(g/m2)
Coating wt.
(g/m2)
Sludge
(g/m2)
Classical
1.3 – 1.5
1.5-3.0
10.1-11.7
Flex
0.4 – 0.6
0.0-0.25
3.1-4.7
70% Al Sludge Reduction!
BONDERITE® Flex Corrosion Performance
Cold-Rolled Steel
Cold Rolled Steel
6 wks, Cyclic Corr. Test L-467
BONDERITE® 2798
Standard Process
BONDERITE® Flex Corrosion Performance
Electro-Galvanized Steel
Electrogalvanized Sreel
6 wks, Cyclic Corr. Test L-467
BONDERITE® 2798
Standard Process
BONDERITE® Flex Corrosion Performance
Hot-Dipped Galvanized Steel
Hot-Dipped Galvanized Steel
6 wks, Cyclic Corr. Test L-467
BONDERITE® 2798
Standard Process
BONDERITE® Flex Corrosion Performance
Aluminum
Aluminum
6 wks, Cyclic Corr. Test L-3190
BONDERITE® 2798
Standard Process
BONDERITE® Flex Corrosion Performance
Ford Cyclic Corrosion Test
CETP L-467, -3190, 6 weeks
12.0
Flex Process
Classical Zinc Phosphate
mm creep from scribe
10.0
8.9 9.1
8.0
6.0
4.8
4.0
1.7
2.0
3.1
2.7
2.6
1.8
1.7
1.1
0.0
Cold-Rolled
Steel
ElectroGalvanized
Steel
Hot-Dipped
Galvanized
Steel
Galvannealed
Steel
AA6111
BONDERITE® Flex Process Overview
BONDERITE® Flexible Pretreatment Process
• Up to 85% Aluminum substrate
• Process Cost Savings compared to standard phosphating of Aluminum
• Excellent corrosion performance on aluminum
Benefits
Application and Process Examples
BONDERITE® Flex – Scanning Electron Microscopy (SEM) 2,000X
Deposits uniform conversion coating
• Selective deposition on each substrate
• Zinc phosphate on CRS, EG, HDG
• Zirconium-oxide coating on Al
Meets performance specifications
• Promotes paint adhesion
• Excellent corrosion protection
Cold Rolled Steel
Cleaner
Electrogalvanized
Zinc
Rinse Surface
Cond. Phosphate
Aluminum
Rinse
Zr Oxide Rinse
Audience Q&A
Speaker Information:
Kevin Woock
Kevin.woock@henkel.com
Dr. Bruce H. Goodreau
Bruce.goodreau@henkel.com
www.henkelna.com/lightenup
@HenkelAuto_NA