Global Automotive Lightweight Materials

Applications of Adhesive Bonding To Enable

Joining Of Multi-Materials
April 25th 2013

Daryl Greig

Lotus
LotusCars Limited
Cars Limited
Introduction Lotus Cars

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Overall Construction

Elise / Exige:
Volume: 1500 2000 p.a.
Tub: Anodised aluminium
Upper: Composite Panels
Rear: Steel subframe bolted
Front: Composite front module bonded

Evora:
Volume: 1000 1500 p.a.
Tub: Anodised aluminium
Upper: Composite Panels
Rear: Steel subframe bolted
Front: Aluminium front module bolted

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Tub Construction
Semi monocoque tub concept
Multi material construction
No primer or overall paint finish
Bolted and bonded structural interfaces
3 types of Bonded joints:
Al / Al, Elise/Exige
Dow XD4600 single part heat cure
1.95kg adhesive, Evora 3.5kg
Al / composite
Dow Betamate 2810
Composite / composite
Dow Betamate 2810
Panels bonded and bolted to complete BIW
Possible common features to higher volume multi material BIW
designs depends on E-coat & paint provision
Kerb weights:
Elise: 720kg (Mk1)
Exige: 1176kg
Evora: 1390kg
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Evora - Torsion and Bending Stiffness Contribution
Full GBIW

Bare Tub
Stiffness Torsion Bending
kNm/deg kN/mm

Baseline Roadster 14 8

Lotus Cars Limited Coupe (GBIW) 26 10.5 5

 Evora Structural Composite Panels
Key
CSM Chopped strand mat
FV - Fibre volume
RTM - Resin transfer moulding
ICS - injection compression
system
UD - Unidirectional
Windscreen surround (WSS)
ICS/RTM 3mm-5mm Foam
cored
CSM and 0/90 UD Stitch mat
in A pillar and header. 23%
FV
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Roof panel ICS/RTM
2.5mm CSM and +/-45
UD Stitch Mat.
23% FV
Rear Bulkhead RTM
3.5mm CSM
23% FV
Body Side ICS/RTM 2.5mm-5mm.
Foam cored cant rail
CSM and 0/90 UD Stitch mat in A
pillar and cantrail. 22% FV
Bonded composite body panels are structural unlike Elise
Bonded to tub with Betamate 2800 series and large bond
areas
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Bonding Similar / Dissimilar Materials Challenges

1. Joint design for functionality Stiffness and strength

Design for load bearing joints
Predictive analysis of joints static and dynamic behaviour at extremes of performance envelope
Testing to back up engineering static / dynamic / high / low temp.

2. Pretreatment / Surface prep for Durability

Prediction of useful life through accelerated test
Component tests
Chamber tests whole structures
Vehicle Test
Correlation to recognised standards of life Welded steel to bonded aluminium

3. Manufacturing Process control & Repeatability

Substrate surfaces and surface preparation
Adhesive contact
Manufacturing variables Extrusion, pretreatment, curing, open time, contaminants, transport.
Tracability
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1. Design - Composite Front Module- Multi Functional Component

7.5kg, 75kJ absorbtion Protects tub up to speeds of 25 mph

420mm crushable length
Front impact energy absorber
Replaceable in service
0 deg, offset and 30 deg
Variable wall thickness front to rear
Cooling Module
Clamshell Support support

Radiator duct
Auxiliary light
intake / exit
mounting Tow Bar Mount Heater Intake
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Bonded Joint Design A Closer Look

Section1 Al/Al

Section2 Al/ Composite

Section 3 Comp / Comp

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Section 1 Al / Al

Surfaces SAA anodised for pretreatment,

Bracing ribs
corrosion protection and visual finish

Interlock detail
for adjoining
extrusions

Spew fillet wiped

for moisure
expulsion

0.2mm Ribs -
Bond gap
control

Cutback detail for fastener Mechanical

access and progressive Fasteners Riv
failure mode from front bonding

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Section 2 Al / Composite

Corner load Shear / compression planes

distribution braces for joint

Bond gaps
controlled by
assembly
fixture

Mechanical attachment
plane

Composites
Surfaces primed
Design features aligned for bonding
correctly for load bearing

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Section 3 Composite / Composite

Load bearing Bond gaps controlled by

corners Hex made assembly fixture
of 2 mating sections

Low modulus adhesive with Composites Surfaces

large bond areas primed for bonding

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1. CAE - Riv Bonding Development Adhesive Strength
Correlation
Lap Shear Strength Analysis and Test

Dynamic Strength Test data

Static Strength
Test Data

Dynamic Strength
FE Model Correlation
Upper Bound
Dynamic Test
Drop Rig
Dynamic Strength
FE Model Correlation
Lower Bound
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 1. CAE - Riv Bonding Development Adhesive Strength
Correlation
T Peel Strength Analysis and Test

Dynamic Strength
Test data

Dynamic Strength
FE Model
Correlation Upper
Bound

Dynamic Strength
FE Model Correlation
Lower Bound

Upper and Lower bound values used in crash

FE models to envelope possible failure modes Static Strength Test Data
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1.Tests for Joint Functionality Box Joint Tests

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2.Durability and Life prediction
Technology project to develop bonded aluminium tub.
Set up to work with partners:
Suppliers: Hydro, Ciba
Technologists: TWI, AEA, Alcan,
Key Universities UK and Europe
Others OEMs, Professors..
Preliminary testing for adhesives, fastener and pretreatment selection
8 Major phases of core testing to Explore effect of manufacturing variables on performance
Confirmatory corrosion tests to complete correlation of life prediction and confirm production
specs for anodising, coatings , fixings, interfaces for galvanic protection and transport
packaging materials

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2.Durability and Life prediction
Stress Humidity & SWAAT

Proving Ground Rig Tests

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 2. Durability - Link Proving Ground to Test exposure (Steel)
exposure
87 days

Component test System test Vehicle test Correlation

SWAAT / Stress SWAAT / Proving
Humidity / Proving Proving ground
Dynamic impact ground Ground
Proving Ground

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2.Durability and Life prediction
Correlation SWAAT to Proving Ground

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3.Manufacture

Supplier is a wholly owned subsidiary of Group Lotus - LLS

Supply chain for extrusions and surface treatment is tightly controlled e.g. SAA chemistries
controlled by manufacturing specification. Test parts bonded and tested with every batch
Adhesive contact Adhesive robot applied to approved patterns for complete coverage
Tracability Trace on adhesive, aluminium, pretreatment and curing. Parallel tests of parts with
every assembly made.
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 The future at Lotus

Functional integration Careful design

Sandwich materials Lightweight and quiet
Overall mix of materials
Reasonable cost of ownership service / repair
Credible supply partners
Tooling to allow adventurous design

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Conclusions

Multi material constructions are possible, even without e-coating and painting the final assembly

Bonding durability life can be simulated to an extent by accelerated ageing

Durability of bonded joints is achieved in real time exposure

Innovation in automotive architectures involves design innovation as well as materials technology

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END

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