enabling vehicle lightweighting with advancements in surface treatment and adhesive technologies...

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 WoockGlobal Market Segment Manager – Body-In-WhiteAdhesive Technologies – Automotive, Henkel

Automotive Market Drivers and Focus

Source: EIGHT REDUCTION IN AUTOMOTIVE DESIGN AND MANUFACTURE ; Published by SupplierBusiness, IHS Automotive, 2012

Lightweighting Market Drivers Targets to Enable

• Increasing Regulatory Environment

• Cost / Availability of Fuel

• Emerging Market Growth, Urbanization

• Global Platform Development

• Segment Consolidation

• Stamping & Assembly Infrastructure

• 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)

Summary: Focus on enabling materials and processes which allow OEMs and Tier Ones to achieve Body-In-W Weight Reduction

Convergence of Global Emission and Fuel Economy Regulations

Source: The International Council on Clean Transportation, Passenger Vehicle Greenhouse Gas and Fuel Economy Standards: A Global Update2011

100

120

140

160

180

200

220

240

260

280

2002

2003

2004

2005

2006

2007

2008

2009

2010

2011

2012

2013

2014

2015

2016

2017

USA CAN EU AUS JAP CHN SKO

GR

AM

S C

O2

PE

R K

ILO

ME

TE

R N

OR

MA

LIZ

ED

TO

NE

DC

TE

ST

CY

CL

E

CO2

0

20

40

60

80

100

120

2012 2013 2014 2015 2016 2017 2018

EU AP MEA NA LA

Market Research: Global Auto Production

Source: 2013 March IHS AutoInsight Data

CAGR (2012-2018) = 4.0%

CAGR 2012-18

EU 2.8%

AP 4.9%

MEA 6.2%

NA 2.3%

LA 5.8%

Total 4.0%

Regional Production Forecast: 2012-2018

0

5

10

15

20

25

30

35

C B D A FF E CFF MFF

%o

f M

ix

CY 2012 CY 2018


A Segment -0.2%

B Segment 2.4%

C Segment 1.3%

D Segment -1.0%

E Segment -0.6%

FF Segment -0.8%

Mini FF Segment 0.1%

Compact FF Segment -1.2%


Shifts in Vehicle Segment Production Volumes: 2012-2018

Volume Variance


Source: 2013 March IHS Conference: Successful Global Planning -Detroit

59484430

22

1918

12

0

10

20

30

40

50

60

70

2002 2007 2012 2020

0

5

10

15

20

25

Platforms over 500K units

Ave. Programs per platform

“Mega” Platforms over 500K units per year and number of programs

184

230

0

50

100

150

200

250

Units Per Platform (000s)

Top 25 Global OEMs 2012-2018Average Number of Units/Platform

Global Platforms and Program Consolidation: 2012-2018


Vehicle Lightweighting Trends

2009 1 2010 1 2011 1 2025 2

Regular steel 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

1 American Chemistry Council2 Ducker Worldwide

• The average vehicle will be 400 pounds lighter by 2025 2

• Average materials content of North American light vehicles (pound/vehicle)

Key Material Growth Rates versus Market

Market CAGR Growth Rates 2010-2018

14%

4.2%

0%

2%

4%

6%

8%

10%

12%

14%

16%

Aluminum Auto Build


Aluminum in Automotive: SAE World Congress 2012: Contributors : SAE and Aluminum in Transportation Asso.

46%57%

16%9%

12%12%

25%22%

0%

20%

40%

60%

80%

100%

120%

2012 2025

Steel Aluminum Other Metals Non-Metals


Percent of Automotive Material Mix

Aluminum in Automotive: SAE World Congress 2012: Contributors : SAE and Aluminum in Transportation Asso.

• 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 - key focus lightweighting material to 2018

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

HENKEL TECHNOLOGY MASS REDUCTION TREE EQUIVALENT

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

Henkel technologies account for nearly 100 kilograms in mass savings for every vehicle; the environmental equivalent of planting 19 trees

Adhesives and surface technologies play a central role inintroducing light weight materials

• 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

Enabling light weight materialsTEROSON® Structural Adhesives

• Provides performance across the widest temperature range

• Reduces or eliminates welds

• Enables multi-metal design for structural lightweighting

TEROSON® Epoxies: 5089 – Impact Resistant Structural EpoxyTEROSON® Epoxies: 5089 – Impact Resistant Structural Epoxy

BenefitsBenefits Application Examples & Value EnhancementApplication Examples & Value Enhancement

• 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

Enabling light weight materialsTEROSON® Aluminum Stress Durable Adhesive

• 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

TEROSON® 5100 - Heat Cured Aluminum Stress Durable AdhesiveTEROSON® 5100 - Heat Cured Aluminum Stress Durable Adhesive


• 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

Enabling light weight materialsTEROSON® NVH and Sealing Solutions

• Superior acoustic performance

• Excellent sealing capabilities

• Robust performance

• Assist large product range for multiple OEM’s and applications

TEROSON® NVH and SealingTEROSON® NVH and Sealing


• 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

Enabling light weight materialsTEROSON® High Damping Foam

• Significant Damping

effect over conventional

materials

• Enables lightweight materials

• Eliminates process waste

• Increases process efficiency

TEROSON® High Damping FoamTEROSON® High Damping Foam

BenefitsBenefits Value EnhancementValue Enhancement

• 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

Enabling light weight materialsTEROSON® Structural Inserts

• Locally reinforce body structure to avoid lag

• Transparent to existing processes

• Allow design flexibility

• Assists in weight saving strategies

TEROSON® Structural InsertsTEROSON® Structural Inserts


• 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)

Enabling light weight materialsBONDERITE® M-ZN 2798 Pretreatment

• 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

BONDERITE® M-ZN 2798 Flexible Paint Pretreatment ProcessBONDERITE® M-ZN 2798 Flexible Paint Pretreatment Process


Henkel solutions will help you achieve your lightweighting priorities

1. We enable light-weight construction with innovative products and processes.2. We contribute to the realization of future CO2 emission targets.

3. 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. GoodreauTechnical Director R&D

Surface Treatment Platform NA, Henkel

1. Classical Zinc Phosphate Overview

2. Advantages/Challenges of Aluminum Intensive Vehicles

3. BONDERITE® Flex Process

Agenda

Classical Zinc Phosphate Overview

M0 M+n + ne-

Zn(H2PO4)2M+n

e-

pH increase2H++e- H2

H+

H+H+

Zn3(PO4)2

anode cathode

bulk solution

Classical Zinc Phosphate Overview

E-coat 20-25m

Primer 20-50 m

Basecoat 15-40m

Clearcoat 35-50m

Zinc 20-25m

Steel

<1 m !

Classical 7-Stage Zinc Phosphate ProcessCRS, Zinc and Aluminum

Clean Activate Zinc Phosphate Post TreatmentRinse Rinse Rinse

CRS HDG Al

conveyer directionconveyer direction

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 Increased Al sludge

Increased Sludge can result in:• Increased Maintenance• Deposition on Horizontal surfaces • Drag-in to later stages• Dirt-in-paint

1.0g Al 1.0g Al 7.8g Na3AlF6 (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

Rinse

BONDERITE® M-PT 54NCZirconium Oxide•Post Rinse for Zinc Phosphate •ZrO2 Conversion Coating on Aluminum

RinseClean Activate Zinc Phosphate Post TreatmentRinse Rinse Rinse

conveyer directionconveyer direction

BONDERITE® M-ZN 2798Zinc Phosphate •Reduced Free F- Usage•Zinc Phosphate on CRS and Zn only•Phosphate on Al inhibited

BONDERITE® Flex Process Coating Characteristics

Zinc Phosphate on the Steel and Zn substrates only

CRS HDG AluminumCRS HDG Alu

ZrO2 coating

Zirconium Oxide on Aluminum

1000x 5000x

BONDERITE® Flex Process ExamplesZirconium Oxide

BONDERITE® Flex Environmental BenefitsSludge Reduction

ProcessAl 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

Sludge Reduction with the Flex Process

70% Al Sludge Reduction!

BONDERITE® Flex Corrosion PerformanceCold-Rolled Steel

Cold Rolled Steel6 wks, Cyclic Corr. Test L-467

Standard ProcessBONDERITE® 2798

Electrogalvanized Sreel6 wks, Cyclic Corr. Test L-467


BONDERITE® Flex Corrosion PerformanceElectro-Galvanized Steel

Hot-Dipped Galvanized Steel6 wks, Cyclic Corr. Test L-467

BONDERITE® Flex Corrosion PerformanceHot-Dipped Galvanized Steel


Aluminum6 wks, Cyclic Corr. Test L-3190


BONDERITE® Flex Corrosion PerformanceAluminum

BONDERITE® Flex Corrosion Performance

Ford Cyclic Corrosion TestCETP L-467, -3190, 6 weeks

8.9

1.7 1.8 1.71.1

9.1

2.6 2.73.1

4.8

0.0

2.0

4.0

6.0

8.0

10.0

12.0

Cold-RolledSteel

Electro-Galvanized

Steel

Hot-DippedGalvanized

Steel

GalvannealedSteel

AA6111

mm

cre

ep f

rom

scr

ibe

Flex Process

Classical Zinc Phosphate

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

• Up to 85% Aluminum substrate• Process Cost Savings compared to standard phosphating of Aluminum• Excellent corrosion performance on aluminum

BONDERITE® Flexible Pretreatment ProcessBONDERITE® Flexible Pretreatment Process

BenefitsBenefits Application and Process ExamplesApplication and Process Examples

BONDERITE® Flex Process Overview

BONDERITE® Flex – Scanning Electron Microscopy (SEM) 2,000X

Cold Rolled Steel Electrogalvanized Aluminum

Cleaner Rinse SurfaceCond.

ZincPhosphate

Rinse RinseZr Oxide


Application and Process ExamplesApplication and Process ExamplesBenefitsBenefits


Application and Process ExamplesApplication and Process Examples

Audience Q&A

www.henkelna.com/lightenup@HenkelAuto_NA

Speaker Information:Kevin [email protected]

Dr. Bruce H. [email protected]

Speaker Information:Kevin [email protected]

Dr. Bruce H. [email protected]

enabling vehicle lightweighting with advancements in surface treatment and adhesive technologies...

Documents

henkel slide

global auto production

global oems

ihs automotive

market research

automotive market drivers

average vehicle

ihs autoinsight data