Composites Use In Heavy Truck Ed Zenk Ed Zenk Composite Materials Engineer, International Truck & Engine Corp. Composite Materials Engineer, International Truck & Engine Corp.

Current Materials Spray-up/lay-up Spray-up/lay-up Cold mold Cold mold SMC SMC RTM RTM

Parts Using Composites Roofs Roofs Hoods Hoods Fairings Fairings Doors Doors Bumpers Bumpers Reinforcements Reinforcements

Differences with automotive Larger parts Larger parts Severe service applications Severe service applications Lower volumes Lower volumes Cosmetics (colors, surfaces) Cosmetics (colors, surfaces)

New Materials/Process LPSMC LPSMC UV Cured materials UV Cured materials Advanced Composites (Carbon fiber) Advanced Composites (Carbon fiber) Dicyclopentadiene (DCPD) Dicyclopentadiene (DCPD)

New Applications Frames Frames Cabs Cabs Under-the-hood Under-the-hood

Advantages Balanced Mechanical Properties Low Temperature Impact to –40°F Excellent Dimensional Stability -20°F to 175°F 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 Liquid Molded DCPD for Heavy Truck

Mechanical Properties Property ASTM Method Value Density, g/cm 3 (lbs/in 3 )D (0.037) 24 Hr. Water AbsorptionD % Tensile Modulus, GPa (Ksi)D (275) Tensile yield, MPa (Ksi)D (6.8) Flexural Modulus, GPa (Ksi)D (273) Flexural 5% strain, MPa (Ksi)D79070 (10.1) Yield StrainD6384.7% Rockwell HardnessD785R114 Notched Izod Impact, J/m 23  C (73.4   C (-40  F) D (8.7) 106 (2.0) Compression Strength, MPa (Ksi)D (8.5) Shear Strength, MPa (Ksi)D (7.2) 264 psi,  C (  F) D (226) (3) Glass Transition Temperature,  C (  F) DMA (4) >138 (>280) Coefficient of Thermal Expansion, m/m/  C (in/in/  F) D x10 -6 (48.8x10 -6 ) Dielectric Constant 73  F D Dissipation Factor 73  F D Shrinkage in/in (mm/mm) Poisson’s Ratio ( ) 0.39 Flame Class Rating (5) ULHB

Manufacturing Improvements 90-95% FTQ vs % on previous version 90-95% FTQ vs % on previous version Average of 1.5 passes through paint versus 2.5 to 3 passes for 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 Greatly reduced prep time in plant prior to paint

Cost-1997 DCPD was 90.0% of HSU hood in piece price DCPD was 90.0% of HSU hood in piece price 61.3% increase in tooling cost 61.3% increase in tooling cost Payback achieved in the fourth year Payback achieved in the fourth year Annual Volume 3000 units Annual Volume 3000 units

Cost-2000 DCPD was 70.0% of HSU hood in piece price DCPD was 70.0% of HSU hood in piece price 105.6% increase in tooling cost 105.6% increase in tooling cost Payback achieved in second year Payback achieved in second year Annual volume 6000 units Annual volume 6000 units