Lightweighting
strategies with
TALC
in automotive TPOs
Piergiovanni Ercoli Malacari
[Link]@[Link]
IMI Fabi Spa – Milano – ITALY
International Polyolefins Conference
Houston, TX - February 24th-27th 2019
Takeaway messages
• IMI Fabi GLOBAL approach to AUTOMOTIVE
industry
• TALC is a functional mineral used to improve
properties of TPOs
• The right TALC selection allows to different
lightweighting strategies
Background
• Stringent emission regulations for vehicles
CO2 emission
180 171
159
160
CO2 emission [g/km]
140 127 125 121 115 117
120
95 97 95
100
80 70
60
40
20
0
2013 2021 2025 2013 2020 2025 2012 2020 2025 2013 2020 2025
Source: ICCT/Roland Berger
• Need to lower GHG emissions/fuel consumptions
• Relevant amount of talc modified TPOs in vehicles
• Lightweighting contributes to such process
“GLOBALTY”
GLOBAL SPECIALTY
Global every product
availability of expresses its
the product best for a
range specific role
GLOBALTY
GLOBALTY Novel talc
is the new mineral product
product range range for
specifically developed
automotive
for automotive TPOs
GLOBALTY
Lightweighting approach with TALC
Low Density: reduction of TPO specific
gravity by lowering talc loading
Thin parts: items down gauging by
using stiffer TPOs
Foaming: talc as functional nucleating
agent for TPO foaming
Low density
• considering to keep the 1.15
same item dimension 1.10
(=same volume), the easiest y = 0.0066x + 0.8989
way to lower weight is to
Specific gravity [g/cc]
1.05
reduce the material
specific gravity (SG). 1.00
• In talc modified TPOs, 0.95
because of the higher SG of
talc, the only possibility is to 0.90
minimize the talc loading
0.85
0 5 10 15 20 25 30
Talc content [%]
Rigidity of talc in TPOs
•Talc increases stiffness in polymers
•Excellent for PP/TPO modification (highly
hydrophobic, easy compatible with
polyolefins)
•Highly micronized talc grades are
preferred for best results
Some talc grades in TPO modification
Fineness Specific Color
Class Name Compacted D50 laser surface CIE L [-]
[mm] [m2/g]
FINE HTP2 N (*) 8.5 8.0 96.5
MICRO HTP05c Y 5.5 11.0 96.5
HIGHLY
HVTextra Y 12.0 20.0 96.5
ENGINEERED
(*): available in compacted form too
Stiffness-to-toughness trade-off
23
Impact IZOD notched [kJ/m2]
22
21
20
19 HTP2
20-30% higher stiffness HTP05c
18
17 HVTextra
16
15
1300 1400 1500 1600 1700 1800 1900 2000
Flexural Modulus [MPa]
TPO composition→ block copo PP:POE = 2.95:1.00 (w/w) + 20% TALC
TPO rigidity vs TALC loading
3000
HTP2
y = 56.315x + 753
2500 HTP05c
Flexural modulus [MPa]
HVTextra
y = 40.909x + 753
2000
y = 33.72x + 753
1500
1000
500
0 5 10 15 20 25 30 35 40 45
Ash content [%]
TPO composition→ block copo PP:POE = 2.95:1.00 (w/w) + TALC
Case study: density reduction
• Target: to match 20% talc TPO (SG: 1.03 g/cm3) stiffness with
lower SG.
Equivalent
Flex
Talc @ 20% loading of Final density Weight
modulus
loading HVTextra [g/cm3] saving [%]
[MPa]
[%]
HTP05c 1571 14.5 0.995 3.5
HTP2 1427 12.0 0.978 5.1
Weight reduction percent when TALC
HVTextra is used at lower loading to get
the same final Flexural modulus
Case study: density reduction (cont’d)
2100 HVTextra
1900
Flexural Modulus [Mpa]
HTP055c
1700
1500
1300
HTP2
1100
900
12.0% 14.5%
700
0 5 10 15 20 25
Talc loading [%]
TPO composition→ block copo PP:POE = 2.95:1.00 (w/w) + TALC
Thin Parts
•Other possible lightweighting solution is
to lower the item volume, reducing the
part thickness
•Part functionality must be granted with
new design solutions, but also with
improved material performances
Case study: down gauging in beam
deflection
Beam thickness
Beam variation to
Thickness achieve same
deflection under
same loading
→ Thickness is linked to material stiffness
Some talc grades in TPO modification
Fineness Specific Color
Compacte
Class Name D50 laser surface CIE L [-]
d
[mm] [m2/g]
FINE HTP2 N (*) 8.5 8.0 96.5
MICRO HTP05c Y 5.5 11.0 96.5
HIGHLY
HVTextra Y 12.0 20.0 96.5
ENGINEERED
ULTRA FINE HVTultraC Y 3.3 12.0 97.0
(*): available in compacted form too
Stiffness-to-toughness trade-off
31
Impact IZOD notched [kJ/m2]
29 Better impact-to-
27 stiffness trade-off
25
HTP2
23
HTP05c
21
19 HVTextra
17 Better stiffness HVTultraC
15
1300 1400 1500 1600 1700 1800 1900 2000
Flexural Modulus [MPa]
TPO composition→ block copo PP:POE = 2.95:1.00 (w/w) + 20% TALC
TPO rigidity vs TALC loading
3000
HTP2
2500 HTP05c y = 56.315x + 753
Flexural modulus [MPa]
HVTextra y = 48.399x + 753
2000 HVTultraC y = 40.909x + 753
y = 33.72x + 753
1500
1000
500
0 10 20 30 40 50
Ash content [%]
TPO composition→ block copo PP:POE = 2.95:1.00 (w/w) + TALC
Case study: down gauging in beam
deflection (cont’d)
Loading Modulus Thickness SG volume Weight Weight
[%] [MPa] [mm] [g/cm3] [cm3] [kg] reduction
HTP2 20 1427 2.80 1.03 699 0.72 ref
20 1571 2.71 1.03 677 0.70 3.2%
HTP05c
30 1980 2.51 1.10 627 0.69 4.5%
20 1721 2.63 1.03 657 0.68 6.1%
HVTultraC
30 2205 2.42 1.10 605 0.66 7.9%
20 1879 2.55 1.03 638 0.66 8.8%
HVTextra
30 2442 2.34 1.10 585 0.64 11.0%
TPO composition→ block copo PP:POE = 2.95:1.00 (w/w) + TALC
Case study:
down gauging
20%
HTP2- REF
data in the circle indicate the weight saving percent
20% talc 3.2% 6.1% 8.8%
Circle size indicates the part weight
loading
30% talc
4.5% 7.9% 11.0%
loading
HTP05c HVTultraC HVTextra
CASE #A: Toughness Case study:
is highly relevant → down gauging
HVTultraC is the best 20%
HTP2- REF
pick
data in the circle indicate the weight saving percent
20% talc 3.2% 6.1% 8.8%
Circle size indicates the part weight
loading
30% talc
4.5% 7.9% 11.0%
loading
HTP05c HVTultraC HVTextra
CASE #B: Toughness Case study:
is less relevant → down gauging
HVTextra is the best 20%
HTP2- REF
pick
data in the circle indicate the weight saving percent
20% talc 3.2% 6.1% 8.8%
Circle size indicates the part weight
loading
30% talc
4.5% 7.9% 11.0%
loading
HTP05c HVTultraC HVTextra
Foaming
• Foaming is the fastest lightweighting solution, but it
can heavily affect mechanical performances
• Weight saving is achieved by incorporating gas into the
final item significantly reducing the final average SG
• It can be used in specific applications where mechanical
properties are less relevant
• Talc works as nucleating agent in the bubble
growth heterogeneous nucleation process
Foaming (cont’d)
• Thanks it its hydrophobicity and high
lamellarity, TALC is ideal nucleating agent for
bubble growth nucleation:
• Easy dispersible
• Excellent affinity with POs (talc surface wetting)
• Large interface area per dosing unit, for high
efficiency
Some talc grades in TPO foaming
Fineness Specific Color
Class Name Coated D50 laser surface CIE L [-]
[mm] [m2/g]
FINE HTP2 N 8.5 8.0 96.5
MICRO HTP05c N 5.5 11.0 96.5
ULTRA FINE NSultraC Y 3.3 12.0 97.0
Foaming
Filled
HTP2
20%
Talc loading
HTP05c
5%
NSultraC
0.5%
unFilled
Chemical Physical
Blowing Agent Blowing Agent
Some talc grades in TPO foaming
Class Name Suggestion of use
FINE HTP2 Highly filled foamed compounds
MICRO HTP05c Filled PP and TPOs
ULTRA FINE NSultraC Unfilled PP and TPOs
Takeaway messages
• IMI Fabi GLOBAL approach to AUTOMOTIVE
industry
• TALC is a functional mineral used to improve
properties of TPOs
• The right TALC selection allows to different
lightweighting strategies
GLOBALTY
Novel talc
product
range for
automotive
Thank you!
Piergiovanni Ercoli Malacari
[Link]@[Link]
Visit our website
[Link]
