Composites:Applications & Trends in

Automotive Industry

Gokul Venkataraman.

Hyderabad – June 16th - 2012

2

Agenda

• Owens Corning businesses at a glance

• A sneak peek into the India Auto industry

• Composites in Automotive Segment - Advantages & Trends…!

• Summarizing..!

3

Owens Corning businesses at a glance

4

Owens Corning At A Glance

• Founded in 1938, is a leading global producer of residential

and commercial building materials, glass-fiber

reinforcements and engineered materials for composite

systems

• 2011 sales: $5.3 billion

• 15,000 employees in 28 countries

• FORTUNE 500 company for

58 consecutive years

• Residential Insulation

• Commercial & Industrial Insulation

• Residential Shingles

• Roofing Asphalts

• Composites

A Global

LeaderLeading North American

Market Positions

www.owenscorning.com

5A Global Glass Reinforcement Supplier

Owens Corning’s Global Composites

• 2011 sales: $1.9 billion vs. $5.3 billion for

global Owens Corning

• 7,600 employees worldwide

• Nearly 40 plants in 15 countries

• R&D centers in Granville (Ohio), Chambéry

(France), Ibaraki(Japan), Zele(Belgium),

Apeldoorn (Netherlands), Shanghai (China

-coming soon)

6

Power / EnergyWind Energy, Power Plants, Refineries,

Energy Exploration & Transportation,

Other Renewable

TransportationLight Vehicles, Trucks, Other

Water DistributionPotable Water, Sewage, Storage &

Treatment

HousingRoofing, Sanitary, Construction & Other

Aerospace/DefenseAircraft, Military & Security

Composite End-Use Markets

ConsumerMarine, Sports & Leisure, Appliance &

Other

IndustrialFactories, Roads & Bridges,

Communications, Commercial Construction

& Other

www.composites.owenscorning.com

7www.ocvreinforcements.com/solutions/Standard_Reinforcements.asp

Our glass reinforcements are made in

various forms in order to make them

suitable for a variety of processes and

to provide desired thermo-mechanical

and electrical properties

Owens Corning Solutions

Single-End Roving,

Multi-End Roving (OC Hilight™ roving),

BMC/RTP Chopped Strands,

Chopped Strand Mat,

Continuous Filament Mat

Final Applications

Comprehensive Range of Reinforcements

for Each Market

Copyright © iP; Blanchard (FR)

8

Owens Corning Solutions

www.ocvreinforcements.com/hp

High Performance Reinforcements –

Stronger, Stiffer, Lighter

Compared to standard E-glass, enabling

to achieve(*)

• Up to 50% higher strength with S-glass

• Up to 20% higher modulus with S-glass

• End-use parts have higher fatigue

properties

• Up to 80% better impact resistance

• Better aging and corrosion resistance

than E-CR/E-glass

• Better resistance at elevated

temperaturesFinal Applications

(*) Owens Corning testing

9

Auto OE’s Wide Presence Across India..!

10

Passenger Car sales are booming..!

11

Growth continues in Other Vehicles..!

12

Key Automotive Drivers:

Environment > Weight Out, Aerodynamics, Emissions Reduction,..

Occupant & Pedestrian Safety > Higher Performance Components

End of Life Vehicle Legislation > Recyclability…Design, Materials

Financial Performance Issues > Cost Out…Part Integration…Modular Designs

Mass Customization > Less Platforms, more Offers customized to

Customers

Owner Ship > Customer Satisfaction, Robustness, Insurance

Ratings

Paint Out (Cost & Environment) > Paintless Film Based Body Panels

Auto Industry Trends & Drivers

13

Challenges in Automotive segment

• Energy Limitation

– Today, Oil Consumption is over 80 mio. barrels/day and still increasing...

– Oil & Natural gas reserves are limited.

– Substitution energies (biofuel, nuclear, hydraulic, solar, eolian, tidal, ...)

– Production & Technology limitations

– Storage & Transportation issues

• Environmental Concerns

– 16% of global made-made CO2 emissions

comes from Road Transport

– CO2 emission due to human activity are

participating to climate change (wide

agreement).

– Automobile represents an improvement of

life quality

– Sustain the benefits of vehicles

– Reduce environmental impact

14

• Mahindra & Mahindra wants to build an SUV that weighs less than a

tonne…! The company saves 80-90 per vehicle for every kg of weight

loss..!*

• Maruti has saved Rs 147 crore by working on one-gram weight

reductions on components... all because customers want lighter cars

that drink less fuel and cause less pollution..!*

Simplified Borrowed Analogy on Weight Reduction * –

Equivalent of toning down a sumo wrestler to Salman Khan size..!*

* Source – The Economic Times – Oct 18th, 2011

Weight Loss – The latest Trends In Indian Automotive Market

15

Responses to the challenge

• Vehicle Propulsion Technology

– Biofuel

– Natural Gas Vehicles

– Hybrid Electric Vehicle (HEV)

– Fuel Cell Vehicle (FCV)

– Battery Electric Vehicle (BEV)

– Spark Ignited Internal Combustion Engine (SIE)

– Transmission Improvement

• Driveline optimization

• Improved Tire Rolling Friction

• Vehicle Design

– Aerodynamics improvement

– Weight Reduction without compromising on safety & comfort

• Vehicle Downsizing

• Vehicle Design Change

• Selection of Lighter Materials

16

Material Weight Reduction

-100 Kg -0.35 l/100km -9.0 g/km

Owens Corning estimates:

17

Composites in Automotive Segment

188/1/2012

Replacing Traditional Materials

Global Materials Market(metric tonnes)

Source: Industry Statistics; E-Composites; Owens Corning Management Estimates

Wood

Steel

Composites

1.5% Aluminum Plastics

19

Materials in Automobile

• Light-Weight Alternative Materials

• More than 2/3 of car weight is steel

Steel = Material of Choice in Auto

Industry

– Easily Available

– Stiff & Strong

– Easy to form

– Cost affordable

BUT…

Heavy (mild steel density: 7.86 g/cm3)

20

Plastics…Low Density (Light)

Corrosion Resistance

Allow Complex Shape

Diversity of Process & Materials

Non-Conductive

Low Strength

Low Modulus

Poor Dimensional Stability

Steel…High Modulus

Moderate Strength

Dimensional Stability

High Density (Heavy)

Corrosion

Limited Choice of Processes

Conductive

Composites…Low Density (Light)

Corrosion Resistance

Allow Complex Shape

Diversity of Process &

Materials

Non-Conductive

High Strength

Dimensional Stability

Modulus: Medium to High

From Plastics to Composites

21

SMC & BMCCommon Applications

SMC Tailgate

SMC Decklid

Structural

application

Under the hood

applications•Rocker Cover

•Manifolds

•Oil sump

Head Lamp

Reflectors

Pump housings

SMC

BMC

• Injection Molded Valve

Covers

• Circuit breakers

• Electrical insulators

22

Surface Aspect Improvement Technology (SMC)

• Vacuum Assisted Molding (Budd)– Advantages

• De-gazing

– Eliminate porosities

• Increase of Surface Charge

– Reduction of long length waviness

• Low Pressure Molding –LPMC (Crystic Impreg®) – High-Flow Resin system

– 40 bars (instead of 85 bars)

• Tough Class-A SMC (Atryl® Resin)– Low porosity

• Minimization of Paint-Pops

– Less Micro-crackings

Crystic Impreg® is a trademark of Scott

Bader Corporation

Atryl® is a trademark of AOC Corporation© Domofon / shutterstock.com

23

Material Thickness

[mm]

Weight

[kg]

Material

cost /

Part

Invest Total cost per

Assembled

Part

Integration

of

Functions

Steel 0.8 8.7 (100%)

100% 100% 100% Low

Aluminium 1.55.9

(70%)125% 125% 115% Low

Magnesium 2.0 5.2(60%)

225% 150% 175% Low

Composite(GMTex®)

2.5 – 3.5 4.5(50%)

125% 60% 80% High

Weight Reduction Success Story –Spare Wheel Well

GMTex® is a trademark of Quadrant AG

High Level of Function Integration allows Weight Reduction

24

Cost Comparison

• Further Costs Reductions brought by Composites

– Handling Cost

• Less Parts Defects due to Dents & Corrosion

– Assembly Cost

• Parts Consolidation. Savings in Assembly Cost

• Part Manufacturing

– Part Cost strongly depending on

Processing Technique

– Better Cost Positioning for

Composites vs. Steel in Low &

Medium-Series models

26

Advantages of Composites in Auto parts manufacturing

• Part weight reduction vs. steel

• Exceptional surface finish

• Functions integration

• Corrosion free

• High-thermal resistance

• Comfortable Ride

– Noise

– Vibration

– Harshness

©Maksim Toome / shutterstock.com

Battery

Cover

Engine Cover

Front-End

Module

27

Cost Reduction (Fuel consumption & Maintenance)

Clean (CO2 Emissions)

Safety (Cockpit Protection, Part Integrity, Pedestrian Safety)

Comfort (Interior Space, Vibrations & Acoustics')

Personalization (Design, Flexibility Offer, Customization)

Why More Composites? The End-user’s Choice

28

Thank you…

© 2012 Owens Corning, All rights reserved.

www.composites.owenscorning.com