Paul Boughton
In the ongoing search for new ways to reduce vehicle weight, automotive OEMs and suppliers have been looking for a better alternative to steel, aluminium and thermosets for large, aerodynamic, horizontal body panels. Now Sabic Innovative Plastics and Azdel have launched a new hybrid thermoplastic composite grade, Ixis 157 composite, a continuous glass fibre-reinforced sandwich composite.
Ixis 157 composite is said to be the first product launched using high-performance thermoplastic composite (HPPC) technology and provides critical advantages over traditional materials, starting with a 50 per cent weight reduction compared to steel. By adopting IXIS thermoplastic composites, automakers can design cost-effective, lightweight and aerodynamic body panels that will help drive the success of fuel-efficient future models.
Greg Adams, vice president of automotive at Sabic Innovative Plastics, comments: "Together with Azdel we have made tremendous strides with Ixis composites, including the commercialisation of our first grade aimed at off-line painting and the excellent progress toward an online paintable product. We have leveraged our resources around the globe to develop the Ixis materials that have been featured on two of the most successful 'green' concept vehicles in the world: the Chevrolet Volt and the Hyundai Qarmaq. Our investment in these new technologies enables us to continue to provide innovative solutions to address the automotive industry's environmental, performance and cost challenges."
The Ixis composite is composed of a random glass fibre-reinforced core with a glass content (by weight) of approximately 50 per cent, together with skins of continuous unidirectional fibre-reinforced thermoplastic. The skin material enables a Class A paint finish to be achieved, as well as dimensional stability, while the core material aids processing and reduces overall material costs.
Ixis composites are significantly lighter than steel and thermoset resins, with the potential to make a large contribution to improved fuel efficiency. They also offer important performance benefits, including excellent sound-deadening qualities for a quiet ride, and outstanding damage resistance. In comparison to thermosets, which tend to shatter and splinter on impact, and steel, which tends to crumple, Ixis composites rebound, offering better energy absorption for pedestrian safety.
The polypropylene-based 157 grade is designed for off-line painting, and the upcoming 200 grade is intended for online painting and processing through the e-coat process. Both can be recycled. Thanks to a good polymer/glass fibre bond, the material can be granulated and remoulded for other engineering applications.
Unlike steel, Ixis composites enable part integration, such as the insertion of antennas into the roof of a vehicle. Although thermosets have been used in this manner, they are heavier and far more difficult to recycle.
Ixis composites offer a compelling weight advantage over steel, but that is just the beginning. Mike Birrell, director of exterior composites at Azdel, states: "With OEMs facing challenges to reduce greenhouse gas emissions and increase fuel economy, Ixis technology is a cost-effective lightweight alternative to steel. It is also significantly less expensive than aluminium. Further, because Ixis composites are designed for low-pressure compression moulding – a low-energy process – less costly aluminium tools can be used. All these factors add up to a very attractive economic value for automakers and tiers."
Fibre-reinforced composites are widely used in the aviation and aerospace industries. Sabic Innovative Plastics and Azdel have adapted this technology for automotive applications by leveraging the dimensional stability and high-quality surface finish of continuous, unidirectional glass fibre. In contrast to cut fibres, continuous fibres inhibit thermal movement, thereby helping to reduce expansion and contraction of large, horizontal parts when exposed to sun and temperature extremes.
For more information, visit <a href="http://www.sabic-ip.com"target=_blank>Ixis 157</a>
Ixis 157 composite is said to be the first product launched using high-performance thermoplastic composite (HPPC) technology and provides critical advantages over traditional materials, starting with a 50 per cent weight reduction compared to steel. By adopting IXIS thermoplastic composites, automakers can design cost-effective, lightweight and aerodynamic body panels that will help drive the success of fuel-efficient future models.
Greg Adams, vice president of automotive at Sabic Innovative Plastics, comments: "Together with Azdel we have made tremendous strides with Ixis composites, including the commercialisation of our first grade aimed at off-line painting and the excellent progress toward an online paintable product. We have leveraged our resources around the globe to develop the Ixis materials that have been featured on two of the most successful 'green' concept vehicles in the world: the Chevrolet Volt and the Hyundai Qarmaq. Our investment in these new technologies enables us to continue to provide innovative solutions to address the automotive industry's environmental, performance and cost challenges."
The Ixis composite is composed of a random glass fibre-reinforced core with a glass content (by weight) of approximately 50 per cent, together with skins of continuous unidirectional fibre-reinforced thermoplastic. The skin material enables a Class A paint finish to be achieved, as well as dimensional stability, while the core material aids processing and reduces overall material costs.
Ixis composites are significantly lighter than steel and thermoset resins, with the potential to make a large contribution to improved fuel efficiency. They also offer important performance benefits, including excellent sound-deadening qualities for a quiet ride, and outstanding damage resistance. In comparison to thermosets, which tend to shatter and splinter on impact, and steel, which tends to crumple, Ixis composites rebound, offering better energy absorption for pedestrian safety.
The polypropylene-based 157 grade is designed for off-line painting, and the upcoming 200 grade is intended for online painting and processing through the e-coat process. Both can be recycled. Thanks to a good polymer/glass fibre bond, the material can be granulated and remoulded for other engineering applications.
Unlike steel, Ixis composites enable part integration, such as the insertion of antennas into the roof of a vehicle. Although thermosets have been used in this manner, they are heavier and far more difficult to recycle.
Ixis composites offer a compelling weight advantage over steel, but that is just the beginning. Mike Birrell, director of exterior composites at Azdel, states: "With OEMs facing challenges to reduce greenhouse gas emissions and increase fuel economy, Ixis technology is a cost-effective lightweight alternative to steel. It is also significantly less expensive than aluminium. Further, because Ixis composites are designed for low-pressure compression moulding – a low-energy process – less costly aluminium tools can be used. All these factors add up to a very attractive economic value for automakers and tiers."
Fibre-reinforced composites are widely used in the aviation and aerospace industries. Sabic Innovative Plastics and Azdel have adapted this technology for automotive applications by leveraging the dimensional stability and high-quality surface finish of continuous, unidirectional glass fibre. In contrast to cut fibres, continuous fibres inhibit thermal movement, thereby helping to reduce expansion and contraction of large, horizontal parts when exposed to sun and temperature extremes.
For more information, visit <a href="http://www.sabic-ip.com"target=_blank>Ixis 157</a>
