Thermoset composite SMC for on-line painting of Automotive Body Panels Speakers : Marie-Laure GUEGAN, R&D Manager, IDI Composites Europe Guillaume CLEDAT, SMC Key market developer, CCP Composites 1 Transportation Weight Loss Diet Conference 2013, Stuttgart
Outline of the presentation Painting Process SMC Supply Chain SMC Thermoset Composite E-coating SMC Grade development Commercialization 2 Transportation Weight Loss Diet Conference 2013, Stuttgart
Painting Process Off-line Painting of SMC Parts: Molding Class A SMC Primer Step Painting Assembly Molder / Automotive TIER 1 OEM SMC e-coating Process : Molding SMC e-coating Assembly Cataphoresis Painting Molder / TIER 1 3 Transportation Weight Loss Diet Conference 2013, Stuttgart OEM
Supply Chain Raw materials and equipments manufacturers Compounders Molders / TIER 1 suppliers OEMs Glass fibers SMC formulation Conversion Automotive Peroxides & additives Truck, Bus Resins and additives Agriculture equipments 4 Transportation Weight Loss Diet Conference 2013, Stuttgart
CCP Composites Stallingborough UK UPR, Gel Coats Mississauga & Drummondville, Canada Blend UPR, Gel Coats Drocourt, France UPR, GelCoats, VE Boretto, Italy Miranda Spain Gel Coats USA 7 plants UPR, Gel Coats UPR, Gel Coats Jeonju, South Korea UPR, GelCoats, SMC, BMC, VE Stallingborough UK UPR, Gel Coats Drocourt, France UPR, GelCoats, VE Sao Paulo, Brazil UPR, Gel Coats Pasir Gudang, Malaysia UPR, Gel Coats Miranda Spain UPR, Gel Coats Boretto, Italy Gel Coats : CCP Plant : Tolling/Operating Plant : Center of competence Joinville & Caxias, Brazil Gel Coats Melbourne, Australia Blend UPR,Gel Coats Created in 2011, mergure composite materials activities of Cray Valley, CCP and Progress Plastics A company of Total group Unsaturated polyester and vinylester resin, low profile additive, gel coat and bonding paste manufacturer Sao Paulo, Brazil 950 employees 550 M $ turnover (2011) 19 production : CCP Plant sites on 4 continents Joinville & Caxias, Brazil Gel Coats 10 % of staff dedicated to R&D and technical assistance : Tolling/Operating Plant 5 Transportation Weight Loss Diet Conference 2013, Stuttgart UPR, Gel Coats
IDI Composites International IDI Composites Europe FRANCE Vineuil (41) (SMC/BMC/CIC/MMC) IDI Industrial Dielectrics, Inc. Privately held family company with 6 independent facilities, Global formulator of thermoset composites (SMC, BMC) oriented to customers needs, High Performance oriented product lines with product and customer diversification, Experienced management teams, Unmatched capabilities with over 40 years experience 6 Transportation Weight Loss Diet Conference 2013, Stuttgart
General characteristics of SMC and BMC Two main kinds of thermoset composite compounds : SMC «Sheet moulding compound» Compression molding, larger parts, longer glass fiber (25mm and longer) BMC «Bulk moulding compound» Injection molding, smaller parts, complex parts, shorter glass fiber, lower glass content (about 15 / 20%) Typical composition and main properties: Density : 1.3 to 2 Service temperature : - 30 to +200 C Flexural strength : 120 to 625 MPa Tensile strength : 65 to 440 MPa Design Recyclable Glass fiber Mineral fillers UP resin LP additives 7 Transportation Weight Loss Diet Conference 2013, Stuttgart
Production / Molding - SMC Assemble Painting 8 SIA SFIP Transportation / SFIP Douai Douai 13/06/12 Weight 13/06/12 Loss Diet Conference 2013, Stuttgart
Main barriers to on-line painting Main barriers to on-line painting were identified, five development directions were followed up to achieve the required performances Paint curing @ 200 C Conductivity Painting process «paint popping» issue 9 Transportation Weight Loss Diet Conference 2013, Stuttgart Resin chemistry SMC formulation optimization Shrinkage control Curing catalysis Molding process monitoring Higher thermal stability Compatibility with e-coating Sealed surface material Residual styrene Minimization Material control
Shrinkage control mechanism Low profile or low shrink additives Material microstructure (1) 1 Optimization: VOC emissions Residual monomer migration Release agent migration Much improved paint surface quality versus SMC cosmetic surface properties (2) 2 MEB picture of cured UP resin with PVAc (1) or PS (2) based additives 10 Transportation Weight Loss Diet Conference 2013, Stuttgart
Thermal stability - TGA Weight loss monitoring based on Thermal Gravimetry Analyzer allows to simulate material behavior through the painting process Initial cataphoris simulation - 35min @185 C TGA (Weigth loss %) Rise plateau total Class A standard SMC formulation e-coating SMC Formulation Without 0,9 0,4 1,3 With 0,5 0,3 0,8 Without 0,6 0,4 0,9 With 0,4 0,2 0,6 11 Transportation Weight Loss Diet Conference 2013, Stuttgart
VOC Emissions VDA 278 Reduction of organic compound emissions 632 15 51 0 Standard class A SMC formulation e-coating SMC formulation Molding conditions : 120 sec @ 160/165 C / 2min 12 Transportation Weight Loss Diet Conference 2013, Stuttgart
% prise en masse Solvent uptake SMC solvent uptake after a two hour contact in a Maduri / Amocco test device Solvent : Butyl acetate / Xylene blend (60/40) Stainless steel plate Glass cell Solvant 0,60% 0,50% 0,52% Maduri test +cataphoresis simulation - 35 min @ 185 C O-ring Coupon 0,40% 0,34% 0,30% 0,20% 0,17% 0,10% 0,11% 0,00% Standard class A SMC formulation e-coating SMC formulation 13 Transportation Weight Loss Diet Conference 2013, Stuttgart
Painting process - Heuliez Stage 1 : Cataphoresis line 10 min @ 160 C 14 Transportation Weight Loss Diet Conference 2013, Stuttgart
Painting process - Heuliez Stage 2 : e-coating Degreassing Wiping Primer : 30 to 35 µm thick Curing : 20 @ 150/160 C TEM analysis Thickness measurements Surface correction Blowing Wiping Color base : 15 to 20 µm thick Clear coat : 25 to 30 µm thick Curing : 20 @ 150/160 C Base + clear coat Primer SMC 15 Transportation Weight Loss Diet Conference 2013, Stuttgart
Failure mode analysis 1/3 Failure analysis of painted parts based on SEM and EDX cartography Painting failure agglomeration SEM/EDX Analysis IUT Blois TOURS University Failure due to TIO2 agglomeration in the primer layer 16 Transportation Weight Loss Diet Conference 2013, Stuttgart
Failure mode analysis 2/3 Failure analysis of painted parts based on SEM and EDX cartography SMC failure Cracks SEM/EDX Analysis IUT Blois - TOURS University 17 Transportation Weight Loss Diet Conference 2013, Stuttgart
Failure mode analysis 3/3 Failure analysis of painted parts based on SEM and EDX cartography Handling issue Cl- : NaCl - Sweat Analyse MEB/EDX: LP additive supplier 18 Transportation Weight Loss Diet Conference 2013, Stuttgart
Surface smoothness Improvement of edges (poping suppression) and Long wave surface distortion thanks to molding conditions optimization Surface smoothness measured with BYK Wave Scan system Byk Wave Scan LW SW DOI Target LW < 8 10 <SW< 30 > 82 Std SMC + IMC 4,4 17,5 81,2 e-coating SMC 5,3 27,8 82,0 19 Transportation Weight Loss Diet Conference 2013, Stuttgart
Commercialization SMC e-coating : March 2011 Serial Production, Volume 155T 75.000 parts annually Applications Peugeot 807 Citroen C8 20 Transportation Weight Loss Diet Conference 2013, Stuttgart
Development of SMC e-coating Conclusion No cross contamination of the cataphoreses process between metal and SMC parts Conductive Material allows for electrostatic Painting Process Compatible with metal high temperature painting process Design flexibility of molded parts Reduced part weight, for lighter vehicle weight over metal Commercialization and on-line Painting Reduced scrap rates and improved cycle time due to simplified paint process Colors Management Reduced part costs to OEM's through improved processing, improved cure, and reduced scrap 21 Transportation Weight Loss Diet Conference 2013, Stuttgart
Contacts IDI Composites Europe www.idicomposites.com Marie-Laure GUEGAN R&D manager marie-laure.guegan@idicomposites.fr + 33 (0) 685 037 918 Josy MANTET-GAY Sales director josy.mantet-gay@idicomposites.fr + 33 (0) 630 552 457 CCP Composites www.ccpcomposites.com Guillaume CLEDAT SMC Key market developer guillaume.cledat@ccpcomposites.com + 33 (0) 680 11 29 28 Laurence MARECHAL Marketing Director laurence.marechal@ccpcomposites.com + 33 (0) 618 87 28 47 22 Transportation Weight Loss Diet Conference 2013, Stuttgart