GE Plastics Automotive

Case Study

GE Helps GM Create First Thermoplastic Fenders in a North American Truck Platform with 2006 HUMMER
Breaking New Ground in the Off-Road SUV Category. To design a version of its renowned HUMMER SUVs with smaller dimensions but just as much attitude General Motors Corp. (GM) relied on its longstanding relationship with GE Plastics, Automotive to identify the best materials for 10 key components, including front and rear fenders made of Noryl GTX* resin, which are the first thermoplastic fenders in a North American truck platform. Appealing to consumers who want rugged, off-road capability combined with improved fuel efficiency and smaller overall dimensions, the 2006 GM HUMMER H3, a mid-size SUV, offers performance features such as the ability to climb rocks, ford streams at 20mph, and make 37-feet U-turns. To create this new vehicle, GM chose an array of highperformance materials from GE Plastics to meet the demands of parts ranging from fenders and the roof rack to wheel covers and grille components. GE provided GM with service, design, analysis, testing, and simulation supprot, so that GM could ensure the quality and performance of each part.
GE Plastics, Automotive and General Motors Corp. When GM decided to design a smaller version of its popular HUMMER SUV, the company wanted to make sure the new H3 model would project the same air of rugged confidence as its larger siblings, the H1 and H2, while also reducing fuel consumption. To create a headturning design incorporating lighter materials, GM collaborated with its longstanding supplier, GE - Plastics, Automotive, to identify the best resins for approximately 10 parts. With the multi-year lead times required to roll out a new vehicle, collaboration on the 2006 HUMMER H3 began in 2002. Two of the most important components were the front and rear fenders. To help reduce weight and boost fuel economy, GM engineers wanted to replace these large steel parts with lighter thermoplastic, but were concerned about the demands of the fenders wide stance, i.e., protrusion away from the vehicle body. GM wanted an aggressive look featuring highly defined fenders, but they required a material that would deliver design freedom combined with exceptional dimensional stability, said Tony Shackelford, Automotive Platform Manager, GE - Plastics. Dimensional stability was required to prevent gaps between the fenders and body caused by material shrinkage or expansion during extremes of cold and heat. GM and GE worked together following which GM selected GEs Noryl GTX* 964W polyphenylene ether / polyamide (PPE/PA) resin for the fenders, based on its superior stability in heat and cold, excellent impact resistance, paintability, and design flexibility. The HUMMER H3 is the first truck-platform vehicle in North America to use thermoplastic fenders. Use of the GE material as a metal fender replacement on this vehicle significantly reduced the total vehicle weight. As part of this collaboration, GE performed a thermal analysis of the fenders, as well as several other H3 parts, at its Plastics Processing and Development Center in Pittsfield, Mass. The analysis involved thermal cycling to show how the fenders would behave at high temperatures. GEs Noryl GTX resin exceeded GMs expectations for performance under demanding conditions. Another important component was the roof rack. Originally, GM selected an ionomer from another vendor to mold this large part. However, just six months before the vehicle rollout, the ionomer experienced processing issues. GM again turned to GE this time, for a replacement that would provide improved processability. GE

Noryl GTX* 964W Resin / General Motors Corp. Case Study

recommended Geloy* XP4034 acrylic-styrene-acrylonitrile (ASA) resin for its processing ease, as well as its weatherability without painting. The black Geloy resin is also used to mold the decorative hood louver, which requires dimensional stability and heat resistance in addition to other properties. From a processing standpoint, GE provided an array of specialized

services to support optimal tool design. At the John F. Welch Technology Center in Bangalore, India, GE process development engineers worked with GM suppliers to conduct predictive testing of the mold design using computer simulation, followed by analysis, testing, and modification of the prototype tool. After the tool went into production, GE experts continued to work with the suppliers to resolve any issues.

The other HUMMER H3 components using GEs resins are: mirrors (Cycoloy* MC1300 resin); forward lighting (Lexan* 141R and LS2 resins, and Cycolac* MG38 resin); wheel covers (Noryl GTX 902 resin); front grille (Cycolac MG37EP resin); and grille opening reinforcement (Valox* 508U resin). Details at www.HUMMER.com

About GE - Plastics GE - Plastics is a global supplier of plastic resins widely used in automotive, healthcare, consumer electronics, transportation, performance packaging, building & construction, telecommunications, and optical media applications. The company manufactures and compounds polycarbonate, ABS, SAN, ASA, PPE, PC/ABS, PBT and PEI resins, as well as the LNP* line of high-performance specialty compounds. GE - Plastics, Specialty Film & Sheet manufactures high-performance Lexan* sheet and film products used in thousands of demanding applications worldwide. In addition, GE - Plastics dedicated Automotive organization is an experienced, worldwide competitor, offering leading plastics solutions for five key automotive segments: body panels and glazing; under the hood applications; component; structures and interiors; and lighting. As a Worldwide Partner of the Olympic Games, GE is the exclusive provider of a wide range of innovative products and services that are integral to a successful Games.

For further information, contact: Antony Shackelford Automotive Platform Manager GE - Plastics, Automotive Tel: 248-320-3688 Fax: 248-262-2664 Email: antony.schakelford@ge.com www.geplastics.com

DISCLAIMER: THE MATERIALS, PRODUCTS AND SERVICES OF THE BUSINESSES MAKING UP THE PLASTICS BUSINESS UNIT OF GENERAL ELECTRIC COMPANY, ITS SUBSIDIARIES AND AFFILIATES, ARE SOLD SUBJECT TO ITS STANDARD CONDITIONS OF SALE, WHICH ARE INCLUDED IN THE APPLICABLE DISTRIBUTOR OR OTHER SALES AGREEMENT, PRINTED ON THE BACK OF ORDER ACKNOWLEDGMENTS AND INVOICES, AND AVAILABLE UPON REQUEST. ALTHOUGH ANY INFORMATION, RECOMMENDATIONS, OR ADVICE CONTAINED HEREIN IS GIVEN IN GOOD FAITH, GES PLASTICS BUSINESS MAKES NO WARRANTY OR GUARANTEE, EXPRESS OR IMPLIED, (i) THAT THE RESULTS DESCRIBED HEREIN WILL BE OBTAINED UNDER END-USE CONDITIONS, OR (ii) AS TO THE EFFECTIVENESS OR SAFETY OF ANY DESIGN INCORPORATING ITS PRODUCTS, MATERIALS, SERVICES, RECOMMENDATIONS OR ADVICE. EXCEPT AS PROVIDED IN GES PLASTICS BUSINESS STANDARD CONDITIONS OF SALE, GES PLASTICS BUSINESS AND ITS REPRESENTATIVES SHALL IN NO EVENT BE RESPONSIBLE FOR ANY LOSS RESULTING FROM ANY USE OF ITS MATERIALS, PRODUCTS OR SERVICES DESCRIBED HEREIN. Each user bears full responsibility for making its own determination as to the suitability of GEs Plastics business products, materials, services, recommendations, or advice for its own particular use. Each user must identify and perform all tests and analyses necessary to assure that its finished parts incorporating GEs Plastics business products, materials, or services will be safe and suitable for use under end-use conditions. Nothing in this or any other document, nor any oral recommendation or advice, shall be deemed to alter, vary, supersede, or waive any provision of GEs Plastics business Standard Conditions of Sale or this Disclaimer, unless any such modification is specifically agreed to in a writing signed by GEs Plastics business. No statement contained herein concerning a possible or suggested use of any material, product, service or design is intended, or should be construed, to grant any license under any patent or other intellectual property right of General Electric Company or any of its subsidiaries or affiliates covering such use or design, or as a recommendation for the use of such material, product, service or design in the infringement of any patent or other intellectual property right. Copyright 2005 General Electric Company. All rights reserved. HUMMER is a registered trademark of General Motors Corp. * Noryl GTX, Geloy, Cycoloy, Lexan, Cycolac, Valox, and LNP are trademarks of General Electric Company.

Nov./05