Build your network, Transform your future MEET surveys  Summary Multimaterial assembly (incl.composites) Thermoformable & recyclable composites Survey inputs 3 Survey fields 4 Survey fields & framework Multimaterial assembly : steel, aluminum, low perf. & high perf. composites … Thermoformable & recyclable composites Industries : Mainly focused on automotive & aeronautics industries (nautical industry also potentially concerned) Objective : identify the major needs in terms of R&D programs in these fields 5 Methodology A qualitative approach has been chosen, based on verbal interviews, with open questions, allowing an interactive exchange, with an accurate understanding of the needs expressed Approx. 25 interviews have been carried out with industrial companies & research laboratories Average length of each interview : 1 to 1.5 hour Questions focused on state of the art, market needs, identified R&D topics, technical locks, TRL, remaining R&D effort level, expected time to market … All organizations interviewed are based in France, within Mov’eo’s network 6 Organizations interviewed 7 Organizations interviewed 6% 27% 41% 54% 53% 19% SMEs Big companies Public research Auto Aero Others 8 Survey 1 Multimaterial assembly 9 State of the art Overmoulding of a metal beam by thermoplastics material, mainly assembled by geometric imbrications Spare wheel bowl New C4 Picasso – SMC composite associated to metal flanges inserts, ready for standard spot welding process at OEM Advanced project study - Door frame reinforcement (PSA – DUPONT) - Thermoformed organosheet integrating metal inserts, then backmolded with PA, assembled on the door frame thanks to gluing + mechanical fixtures 10 State of the art Main serial composites applications today in automotive industry are based on a black metal approach, as composites are used as localized applications, integrated in a global standard frame Result is that the new designed composite part has to be assembled with a standard process (spot welding for example), which means to design interfaces with local metal inserts integrated in the composite part. A great step, but result is not optimized in terms of cost and weight reduction In aeronautics industry, solutions are mainly based on riveting and bonding Future aircrafts and automotive structures will be composed of a mix of aluminum-steelcomposites materials Smart solutions have been recently developed in terms of bonding, which is perceived as the main future solution for high structural performance assembly, as a continuous bond between parts is required … nevertheless, serious locks remain in case of hybrid design. For example the automotive industry will probably continue for a long time to impose E-coat process to these multimaterials BIWs … moreover required production cycle time impose to be able to fix rapidly car geometry … and bonding solutions cannot offer this today, that’s why additional mechanical fixtures are necessary … which is also complicated with best in steel solutions (Extra High Strength Steel …difficult to clinch or drill) 11 State of the art Having solutions like bonding is a key positive fact, nevertheless being able to provide repeatable & robust solutions at high production rates is as important, and absolutely necessary : not provided today Developing solutions for rapid quality control of these new assembly systems is also required for a wide application in aircraft & automotive industry : not provided today Ageing concerns of multimaterials assembly have also to be seriously assessed, as not well known at the moment (differential expansion, weather conditions aging, fatigue etc.) Some R&D collaborative projects already on composite solutions, not addressing all issues (LYCOS, DEMOS, FASTLITE, LIMECO, COMPOSTAMP, COPERSIM …) : they focus on providing materials & technological solutions to produce parts, but the challenge now is to assemble all these parts together Research programs seem to exist in Europe concerning composites / metal welding … 12 Top 5 R&D axis identified Ageing of bonding systems at 10 years or more : simplified methods used today are not predictive enough, and above all there is a large variability from 1 OEM to another, complicating the development of efficient & relevant solutions by suppliers  strong need to define new specifications and standards in terms of ageing and characterization methods, fully dedicated to composites and multimaterials assembly Digital simulation so as to be fully predictive, compulsory for safety parts : modelling of assembly systems has to focus first on fatigue & crash concerns in the coming years, and then to take into account high impact of assembly processes Reliability and repeatability : is process control enough to ensure requested quality level + non destructive inspection solutions to be developed, compatible with high production volumes (1 minute time cycle target for automotive) For high performance structural composites : strong need to imagine & develop robust continuous assembly concepts for a multimaterial design, compatible with 1 minute time cycle (parts design, materials, industrial equipments, processes …) Short term needs for SMEs : support in characterization of their products, including after ageing, and in the choices among the solutions offered to them in terms of materials 13 Survey 2 Thermoformable & recyclable composites 14 State of the art Advanced study - Suspension wishbone Thermoformed PA-CF organosheet STRUCTURAL USE BMW 3 door panel – Wood fiber + PP thermoformed design NON STRUCTURAL USE 15 State of the art Most thermoformed composites on the market today are based on thermoset resins and few with thermoplastics (often SMC process) In terms of recycling, main valorization axis for thermosets parts is crushing, then use as a reinforcement in concrete manufacturing and/or burned for energy production Concerning thermoplastics resins, recycling is theoretically easier, as mashed parts could be used to produce new composite parts (even if very high mechanical performance solutions are difficult to mash with existing equipment,…), possibly in applications with lower mechanical performance Thermoplastic resin manufacturers have recently developed & commercialized plates (DUPONT, SOLVAY, LANXESS … mainly polyamide based) ready to used for thermoforming process, with possibility to integrate various reinforcements (carbon, glass … fibers, mainly continuous for high mechanical properties) or mechanical elements, and optionally overmoulded for functions integration Main drawbacks of these solutions : % of wasted material due to the initial rectangular shape, whatever the final shape, limiting their competitiveness 16 Top 5 R&D collaborative axis identified Mixing of thermoset & thermoplastics resins, to combine properties and functions For non or semi structural applications (or in structural apps in addition to others to combine properties) : integration of natural fibers as reinforcements  need to develop processes & equipments adapted to large production scale + properties & performance repeatibility to be improved Digital simulation : R&D work still to be done concerning thermoplastic plates, integrating the impact of the process steps, and also the impact of humidity on resins like PA. For bio based solutions, there is an existing variability in terms of properties that has to be also integrated into modelling so as to propose safe designs For the use of natural fibers, some high manuacturing T°processes are damaging to their performances : a special R&D work on process T° profiles and time cycles has to be done, to preserve their maximum potential and then their competitiveness Also for natural fibers : special work to be done on fiber-resin compatibility, fireproofing & behaviour 17 Outcome 18 Outcome Most of the organizations interviewed announce a strong interest in being involved in new R&D collaborative programs based on these 2 topics, particularly for multimaterial assembly Needs are considered as very short term for most of the topics identified, as use of composites will shortly become necessary although technological locks will still exist (EU CO2 regulation from 2020 for the automotive industry for example) 19 Surveys conducted by : Jérôme Lavernhe IMS Partner 1 av Porchefontaine F-78000 Versailles +33 615 016 119 [email protected] 20 Keep up with us @t : www.pole-moveo.org twitter.com/pole_moveo youtube.com/user/polemoveo linkedin.com/company/mov'eo 21