Composites Use In Heavy Truck

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Composites Use In Heavy Truck

• Ed Zenk
• Composite Materials Engineer, International Truck
  Engine Corp.

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Current Materials

• Spray-up/lay-up
• Cold mold
• SMC
• RTM

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Parts Using Composites

• Roofs
• Hoods
• Fairings
• Doors
• Bumpers
• Reinforcements

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Differences with automotive

• Larger parts
• Severe service applications
• Lower volumes
• Cosmetics (colors, surfaces)

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New Materials/Process

• LPSMC
• UV Cured materials
• Advanced Composites (Carbon fiber)
• Dicyclopentadiene (DCPD)

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New Applications

• Frames
• Cabs
• Under-the-hood

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Liquid Molded DCPD for Heavy Truck

• Advantages
• Balanced Mechanical Properties
• Low Temperature Impact to 40F
• Excellent Dimensional Stability
• -20F to 175F
• Nonmoisture Absorbing
• Outstanding Surface Replication and Paint
  Adhesion
• 98 D.O.I.
• 5B Crosshatch Index
• Standard Two Component Urethane
• Light Weight 1.03 gm/cc

• Low Pressure Processing
• Large, Complex Part Capability
• Numerous Tooling Options
• Low Cost
• Short Lead Time

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Mechanical Properties
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Manufacturing Improvements

• 90-95 FTQ vs. 60-70 on previous version
• Average of 1.5 passes through paint versus 2.5 to
  3 passes for previous version
• Greatly reduced prep time in plant prior to paint

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Cost-1997

• DCPD was 90.0 of HSU hood in piece price
• 61.3 increase in tooling cost
• Payback achieved in the fourth year
• Annual Volume 3000 units

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Cost-2000

• DCPD was 70.0 of HSU hood in piece price
• 105.6 increase in tooling cost
• Payback achieved in second year
• Annual volume 6000 units

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