SPE Automotive & Composites Divisions
8th Annual Automotive Composites Conference and Exhibition ACCE 2008 “The Road to Lightweight Performance”
September 16-18, 2008 Troy, Michigan, USA
Volume 1 of 2
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Copyright© (2008) by the SPE Automotive & Composites Division All rights reserved. For permission requests, please contact the SPE Automotive & Composites Division at the address below. SPE Automotive & Composites Division MSU Management Education Center 811 West Square Lake Road Troy, Michigan 48098 PHONE: 248-592-0765
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TABLE OF CONTENTS Volume 1 Challenges & Opportunities for Automotive Composites .............................................................. 1 Joseph Carpenter
Future Lower Cost Carbon Fiber for Autos: International Scale-Up & What is Needed............ 50 C. David Warren
Composite Materials Technology in Formula 1 Motor Racing ................................................... 109 Gary Savage
ACMA / ACA Study on Composites for Hybrid Electric Vehicles .............................................. 140 David Dyke
Composites in Extreme Sports...................................................................................................... 141 Jan-Anders Månson
Trek's Use of Composites to Lightweight Racing Bikes............................................................. 142 James Colegrove
History of Automotive Composites............................................................................................... 185 Barbara A. Sanders
Driving Innovative Solutions for Tomorrow (no abstract available) ............................................ 186 Matt Tsien
CFRP: What is Needed Next for Mass Production in the Automobile?..................................... 187 Toru Yamanaka
Damage Tolerance Enhancement Using Continuous Fiber Reinforcements Co-Molded with Long Fiber Reinforced Thermoplastics................................................................................ 188 Uday Vaidya, S. Pillay, K. Balaji Thattaiparthasarthy,
A Formulation Study of Long Fiber Thermoplastic Polypropylene (Part 1): The Effects of Coupling Agent, Glass Content & Resin Properties on the Mechanical Properties............ 197 Creig Bowland
E-Coat Sustainable Long-Fiber Thermoplastic Composites for Structural Automotive Applications................................................................................................................ 208 Raman Chaudhari, Manfred Reif, Oliver Geiger, Frank Hening, Alexander Diehl, Andrea Terenzi
Long Glass Fiber-Polypropylene Light Weight Instrument Panel Retainers & Door Modules............................................................................................................................................ 223 Matthew Marks
Linear Polyphenylene Sulfide (PPS) for Thermoplastic Composites........................................ 251 Harsh Bhagat
Low-Gloss, Weatherable, Molded-In-Color PC/PBT Composite for Vehicle Interiors............................................................................................................................................ 291 Edward Kung
New Methods to Produce Reinforced Polyamide-6 for Improved Material Properties in Engineering Plastic Applications........................................................................... 310 Ab van Geenen, K. Titzschkau, J. Bongers
IXIS - Hybrid ThermoPlastic Composite (HTPC) for Horizontal Automotive Panels................ 315 Mike Birrell
GMT Bumper Beam......................................................................................................................... 361 John Shin
Opportunities and Development of Bio-Based Materials for SMC (Sheet Molding Compound) ...................................................................................................................................... 387 Dwight Rust
Characterisation of the Direct-SMC (D-SMC) Process ................................................................ 393 Tobias Potyra, Dennis Schmidt, Frank Henning, Peter Elsner
Lightweight Structural Parts with Rigid Integral PUR Foams .................................................... 400 Stephan Schleiermacher
Advanced Composite Class A Closures - Production Ready or Production Proven? ............ 406 Martin Starkey
Renuva Soy-Based Polyol RIM for Automotive Exterior Applications...................................... 407 Mark Goldhawk, Allan James, Antoine Zafera, Maria Wesolowski, Jim Moore
Samsung's Bioplastics for Automobiles ...................................................................................... 421 Brian Grosser
Recent Developments in Renewable Resource-Based Resins .................................................. 450 Darcy Culkin
Chopped Glass & Natural Fiber Composites Based on a Novel Thermoplastic Epoxy Resin Matrix ......................................................................................................................... 480 C.A. Chmielewski, J. Kaffenberger
Natural Fibers Plastic Composites for Automotive Applications .............................................. 492 Paulo Aparecido dos Santos, João Carlos Giriolli, Jay Amarasekera, Glauco Moraes
Banana Fiber Composites for Automotive & Transportation Applications .............................. 501 Lina Herrera-Estrada, Selvum Pillay, Uday Vaidya
Evaluation of Joining Techniques for Continuous Fiber Reinforced Thermoplastic Composites...................................................................................................................................... 510 Andrew Lizotte, David Cramer
Hybrid Laser Welding of Polymers ............................................................................................... 535 René Geiger, Oliver Brandmayer, Frank Brunnecker, Chris Korson
State-of-the-Art Fastening Technology in Thermoplastics and Thermosets ........................... 542 Joe Gobernatz
Bond-Line Read-Through Investigation for Composite Closure Panels: Initial DOE Results ............................................................................................................................................. 568 Kedzie Fernholz, B. Blair, C.S. Wang, K. Lazarz
Getting Started with Automated Gasketing & Sealing ................................................................ 581 Dave Whitinger
Volume 2 Thermoplastic Film Adhesives for Rear Injection Molding ........................................................ 597 Dieter Rueger
The Use of Cohesive-Zone Models to Analyze the Behavior of Adhesive Joints .................... 621 M.D. Thouless
Adhesives for Automotive Interiors .............................................................................................. 622 Dave Whitinger
Case Study: Tough, Low-Mass Class A SMC............................................................................... 646 Edward Zenk, David Hearn, Kevin Dinan, Robert Seats, Cedric Ball
Reaction Injection Moldable Polydicyclopentadiene (pDCPD) for the Heavy Truck Market............................................................................................................................................... 653 Garland Lee
Multimatic Tailgate Step for Ingress / Egress .............................................................................. 665 Barry Loucks
Introduction of Proven Marine Composite Process for the Commercial Vehicle Market............................................................................................................................................... 682 Fred Buck
Production Scale-Up of New Thermoplastic Composite Resin Formulations: Demonstrating that the Calculated Savings Are Real................................................................. 683 Rena Pomaville
Film Transfer Technology Advancements for Composites........................................................ 698 Ara Asadorian
High Volume Preforming for Structural Applications Using Engineering Fabrics .................. 709 Dan Buckley
Goodbye Machining: Reconfigurable Pin Tooling ...................................................................... 768 Ben Halford
Rapid Manufacturing & Continued Development of Highly Stressed Fibre-Reinforced Plastic Parts: Motorbike Dash Assembly Made by Windform XT and SLS Technology ......... 783 Livia Cevolini, Giampiero Testoni, Stewart Davis
An In Depth Study of Texture Characteristics & Their Affects on Texture Performance........ 794 Phil Maniscalchi
Better Quality Thermoplastic Foams with Nanoclay................................................................... 827 Amit Kumar Chaudhary, Krishnamurthy Jayaraman
Aqueous Nanocomposite Barrier Coatings ................................................................................. 847 Harris Goldberg, Carrie Feeney, Michele Farrell, Douglas P. Karim, Laxmi Samantara
Mechanical & Thermal Investigation of Polyurethane Nanocomposites .................................. 873 Amit Kaushik, Ellen Arruda, Paul Podsiadlo, Ming Qin, Anthony M. Waas, Nicholas A. Kotov
Toughening Mechanisms in Epoxy Matrix Hybrid Composites / Nanocomposites................. 887 Ray Pearson, L. N. Bacigalupo, Y.L. Liang, R. K. Oldak
Clay Nanotubes in Polymer Composites: A Route to Stronger, Lighter & Less Expensive Materials........................................................................................................................ 915 Cathy Fleicher, Michael Duffy, Robert C. Daly, Aaron L. Wagner, Doug Kelley
NanoStructured Polymer Membrane for Fuel Cell Application: Computational NanoTechnology Approach ........................................................................................................... 916 Seung Soon Jang, William A. Goddard III
Opportunities for Plastics Materials / Processes for Under-the-Hood Applications ............... 928 Suresh Shah
Basalt Fibers for High-Performance Composites........................................................................ 978 Alan Murray
Revolutionary Polymer for Metal Replacement in Automotive Applications ......................... 1022 Mike Zimmerman, Charles Buehler, William Rodgers
High Performance Plastic Components for Engine Mount Applications................................ 1049 Hans-Juergen Karkosch, Holger Klink, Diethard Schneider, Scott Bykowski
Machine Augmented Composites Utilizing an Hourglass Shaped Core Element in a Soft Nearly Incompressible Matrix ........................................................................................... 1062 Roston Elwell, T.S. Creasy
Development of a Structural Composite Underbody ................................................................ 1067 Libby Berger, John Fickes, Hannes Fuchs, Erik Banks, Ronald Wlosinski
Advances in High Fiber Composites .......................................................................................... 1084 Frederick Deans
Constitutive Modeling of Polymer Composites made from LBL Manufacturing Technique ...................................................................................................................................... 1098 Harish Iyer, Amit Kaushik, Eugene Kheng, Anthony M. Waas, Ellen M. Arruda
DIGIMAT Multi-Scale Modeling: The Technology & Software Tools for a Predictive Development of Reinforced Plastic Parts................................................................................... 1108 Roger Assaker
Theoretical Simulation of Cure-Induced Deformations of Composite Car Body Panels............................................................................................................................................. 1135 Medhi Kiasat, Hamid Mostofi
Techniques and Results for Fiber Length Distribution Determination as a Function of Thickness in Long Fiber Reinforced Injection Molded Thermoplastics............. 1146 Vlastimil Kunc, Barbara Frame, Jeff Pryor, Ba Nghiep Nguyen, Charles L. Tucker III, Scott Case, Dayakar Penumadu, Eric W. Guffey
Computer Predictions of the Behavior of Fiber-Reinforced Composites During Molding .......................................................................................................................................... 1156 Alejandro Londoño-Hurtado, Lena Marks ,Gerhard Ziegmann, Tim Osswald
Damage Repair of Low Velocity Impacted Woven Thermoplastic Composites ..................... 1163 Uday Sharma, German Reyes
Composite Liftgate Ductility Performance ................................................................................. 1174 Peter Foss
Strain-Life Fatigue Behaviour of Long Glass Fiber-Reinforced Polypropylene..................... 1188 Jackie Rehkopf
Fatigue Life Prediction of Short Fiber Reinforced Plastic Components................................. 1189 Christian Gaier, Helmut Dannbauer, Axel Werkhausen, Robert Wahlmueller
Author Index