Composite Materials Engineering in Henkel:

The perspective of a Total Solution Provider

Dr Christos Derdas Henkel AG & Co. KGaA
JEC World, Paris, March 15, 2017
 Did you know?

that Henkel sells detergents for around 25 billion wash loads

per year and more than 20 hair colorants per second?
that Henkel is the world's number one adhesives producer?
that in almost every new car produced you can find Henkel
adhesive solutions?
... that Henkel adhesives are used in more than 70% of
smartphones produced today?

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 2
Agenda
Henkels
Composites
Portfolio

Engineering
Conclusions
Offer

Micro-
Adhesive
mechanics &
Engineering
Hand Calcs

CAE Toolbox

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 3
Agenda
Henkels
Composites
Portfolio

Engineering
Conclusions
Offer

Micro-
Adhesive
mechanics &
Engineering
Hand Calcs

CAE Toolbox

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 4
Composite manufacturing and integration process
Henkel is a full system provider
Composite Solutions:
1. Composite matrix resins, binders and release agents
2. Composite adhesives
3. Process know-how and engineering

A B

1. 2. 3. 4. 5. 6. 7.
Seminfinished Preforming Mold Inserting Injection Surface Bonding
part preparation preform & curing preparation

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 5
Overview Loctite MAX series
Composites Matrix Resins
Loctite MAX 2 Loctite MAX 3 Loctite MAX 5

Technology: Polyurethane Technology: Polyurethane Technology: Epoxy

Service Temperature up to 90 C Service Temperature up to 110 C Service Temperature > 200 C
Toughness K1C: 1,2 Toughness K1C: 1,3 Toughness K1C: 1,2

Target application: Dynamic loaded parts Target application: Structural and Target application: High temperature
such as springs or stabilizers dynamic loaded parts such as body parts applications such as wheels

Portfolio of different resins tailored to your application needs

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 6
Overview Loctite MAX series
Technology Highlights
TEROSON PU 1711 Loctite UK2015 General Adhesives portfolio

Source: Audi AG Source: BMW

Technology: 1C micro-encapsulated
Polyurethane
Service temperature of -40oC to 150o C
without performance change
Long open time
Technology: 2C- Polyurethane Various 1C-EP, 2C-EP and 2C-PU
Tensile Strength: 24 MPa (100% adhesive available
Elongation) Temperature or room temperature
Excellent adhesion and aging curing
performance w/o pretreatment Low emission products

Multi substrate adhesive with fast curing Diverse portfolio for bonding diverse
Inline bolt bonding, CFRP to CFRP
at room temperature materials (thermoplastics, steel, plastics)

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 7
Agenda
Henkels
Composites
Portfolio

Engineering
Conclusions
Offer

Micro-
Adhesive
mechanics &
Engineering
Hand Calcs

CAE Toolbox

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 8
Why Engineering in Composites?

New
Processes

Multi-material Structures
Composites and
Lightweighting

New Culture Shift

Materials

New
Design
Concepts

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 9
Vision & Placement

Henkel
Automobile

System and
Subsystem
Component
OEM & Tier 1
Subcomponent

Coupons Design house

Constituents

Provide our customers globally with excellent tools, know-how and support
from concept to process
Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 10
Engineering offer

Testing Prototyping
Static & fatigue testing 2 Global Composite Lab
Environmental aging Facilities
Strain rate & vibration
testing
Subcomponent testing
Creep & relaxation
Engineering Know-how Process Know-how
Micromechanics and Hand Processing Effects
calculations Toolbox Process Simulation Input
CAE Toolbox Cards
Water Absorption
Adhesives Engineering

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 11
Henkel Composite Lab Europe and Asia
Fully equipped labs for prototyping and testing
Dsseldorf, Munich
Composite Lab & Heidelberg (DE)
Isogo
HP-RTM machine for Loctite MAX series: (JPN)
PU and EP materials Shanghai
Madison (CN)
380-tonne mold carrier for mold sizes Heights
of 1.3 m x 1.3 m (USA)

2D-Plate mold for material characterizations Composite Lab

and 3D-Leaf spring demonstrator mold Facility Pune(IN)

New Matrix Resins and multi-substrate Adhesives for Automotive large-scale production March 31, 2017 12
Agenda
Henkels
Composites
Portfolio

Engineering
Conclusions
Offer

Micro-
Adhesive
mechanics &
Engineering
Hand Calcs

CAE Toolbox

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 14
Micromechanics & Hand calcs Toolbox
Toolbox contents Toolbox Uses

ESACOMP Resin-fiber combination selection

DIGIMAT Process parameter effects
Altair Partner Alliance
AlphaStar Ply property prediction
CoDA/ LAP Design and sanity check for testing
Own micromechanics code CAE input cards for different volume
fraction than the ones tested
Laminate behavior assessment
New materials assessment
Property Back-calculation

Composite Materials Engineering in Henkel March 31, 2017 15

Micromechanics prediction of ply properties
Loctite MAX3-Glass fiber Loctite MAX3-UD CF Loctite MAX2 Biaxial CF
1.40 1.40 1.20
1.20 1.00
1.20 1.00
0.80
0.80
1.00 0.60
0.60
0.40
0.80 0.40
0.20 0.20
0.60 0.00 0.00
E22 S22t S11c S22c S12 G12 E22 S22t S11c S22c S12 G12 E11 S11t S11c

Validation Extension
Plates manufactured at the composite lab in Heidelberg
Nomenclature
and tested at the Global Engineering Center in Munich E22: 90o Modulus
Loctite MAX2- UD Glass fiber used to calibrate methods S22t: 90o Tensile strength
S11c: 0o Compressions strength
Values are normalized against experimental means S12: In plane shear strength
Error bars indicate the 2 confidence interval G12: In plane shear modulus

New Matrix Resins and multi-substrate Adhesives for Automotive large-scale production March 31, 2017 16
Agenda
Henkels
Composites
Portfolio

Engineering
Conclusions
Offer

Micro-
Adhesive
mechanics &
Engineering
Hand Calcs

CAE Toolbox

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 17
CAE Toolbox

Toolbox contents Toolbox Uses

Hyperworks Static & Crash Analysis
RADIOSS Altair Partner Alliance Modal & other Dynamic Analysis
OptiStruct Moisture Absorption FE calculations
Ansys Input Cards for different
LS-DYNA solvers/customers
Methods for deriving input cards for Customer support
CAE Input cards for process simulation
Post-processing methods (Re)-Design Exercises

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 18
Surrogate Leafspring

Unexpected failure in component level testing

Problem Root cause identified as not tempering the
test article

Partial test results used to back calculate

assumptions of untested properties
Work FE Model developed to simulate test with
untempered, tempered MAX2 & MAX3

Outcomes Root Cause analysis validated

Technical concerns alleviated

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 19
Composite roof concept design

1st Torsional Eigenmode

Design study of a Yaris sedan roof
Objective FE Model from NCAC. Validated to US-NCAP
full wall frontal real crash test

BIW torsional static load

Work First torsional eigen Mode
Frontal Crash 56 Km/h Frontal Crash 56 Km/h

Weight of steel roof : 15 kgr

Outcomes
Weight of CFRP roof: 4 Kgr
~ 70 % Weight saving

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 20
Roding Door

Produce demonstrator for fairs

Acquire /validate capability
Objective Develop common language with potential
customer

FE analysis of door per FMVSS214-S

Redesign and optimization of door via FE in
Work cooperation with Forward Engineering GmbH
Minimal weight gain

2016 JEC Door demonstrator manufactured by

Outcomes
Roding Automobile GmbH
ECCM-17 paper

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 21
Agenda
Henkels
Composites
Portfolio

Engineering
Conclusions
Offer

Micro-
Adhesive
mechanics &
Engineering
Hand Calcs

CAE Toolbox

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 22
Adhesive Engineering Toolbox

Toolbox contents Toolbox Uses

Comprehensive testing and Using FE Modelling to define

interpretation capability requirements and functionalities for
FE Modelling of joints the adhesive

Capability prediction of residual Addressing CTE mismatch problems

stresses coupling cure kinetics and in multi-material joints
viscoelasticity within FE Models Investigating failure modes
Designing new adhesive classes
Support laminate sequence design

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 23
 Understanding and avoiding joints failure modes
Joint Response

Inter Fibre Failure Index

Through-Thickness Stress
in Composite Plies

Address potential failure modes in composite substrates and counteract by

purposeful layup, adhesive grade selection or joint design
Load transfer results in through-thickness parasitic stresses that may drive failure or
delamination in near-interface plies
Stresses affected by modulus and toughness of the adhesive
Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 24
 Composite bonding
Understanding functional requirements
Roof adhesive stiffness range vs vehicle torsional stiffness target

Selecting and proposing the

correct adhesive
Identifying targets for
adhesives development
Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 25
Agenda
Henkels
Composites
Portfolio

Engineering
Conclusions
Offer

Micro-
Adhesive
mechanics &
Engineering
Hand Calcs

CAE Toolbox

Composite Materials Engineering in Henkel: The perspective of a Total Solution Provider March 31, 2017 26
 Conclusions
Composites implementation Resins and Binders Adhesives
Not only a matter of materials
Requires involvement of all actors in the supply
chain
Key are also engineering know-how, testing and
Process & Engineering Know-how
prototyping
Henkel
Offers a comprehensive selection of resins,
adhesives, binders and ancillary materials
Offers prototyping, testing and process know-
how
Offers a comprehensive composites engineering
toolbox as part of being a total solution provider

New Matrix Resins and multi-substrate Adhesives for Automotive large-scale production March 31, 2017 27
Thank you!
Hall 6
Booth D 28