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 [email protected]

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