[Z06] Z06 materials technology
06-11-2006, 10:24 AM
#1
Melting Slicks
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Z06 materials technology
I am poking around the web to try and learn about the materials and processs used on my painted roof C6 (separated 
), and wandered across a link with some interesting info I had not seen elsewhere on the Z-06 carbon fibre fenders. Rather than ignore, it, I thought I would take a minute to share - hopefully someone will find it, and the link of interest.
http://www.plasticstechnology.com/ar...200601cu1.html
), and wandered across a link with some interesting info I had not seen elsewhere on the Z-06 carbon fibre fenders. Rather than ignore, it, I thought I would take a minute to share - hopefully someone will find it, and the link of interest.
Class A fenders of carbon fiber/epoxy for the 2006 Corvette Z06 are the highest-volume application yet (7000 cars/yr) for such a composite in an exterior body panel. The parts weigh 3.5 lb each, vs. 9.5 lb for the RRIM fenders they replace. Average thickness is 1.2 mm vs. 3.5 mm for RRIM. Material cost per fender is around three times that of RRIM, but savings in tooling, scrap, and subassembly (by integrating brackets and eliminating an SMC support piece) make overall part cost competitive.
The parts are autoclave molded by Vermont Composites, Bennington, Vt. Unidirectional carbon tapes reportedly provide a better surface than woven fabric and cost half as much. Toray’s G83 epoxy “snap cures” in less than 10 min at 290 to 300 F. Tooling designed for maximum airflow in the autoclave helped cut overall cycle time to 85 min from the 120 min it took to mold the carbon-fiber/epoxy hood on the 2005 Corvette. The next goal is to bring cycles under 1 hr.
The parts are autoclave molded by Vermont Composites, Bennington, Vt. Unidirectional carbon tapes reportedly provide a better surface than woven fabric and cost half as much. Toray’s G83 epoxy “snap cures” in less than 10 min at 290 to 300 F. Tooling designed for maximum airflow in the autoclave helped cut overall cycle time to 85 min from the 120 min it took to mold the carbon-fiber/epoxy hood on the 2005 Corvette. The next goal is to bring cycles under 1 hr.
06-11-2006, 10:42 AM
#2
Le Mans Master
Originally Posted by TrackNoob
I am poking around the web to try and learn about the materials and processs used on my painted roof C6 (separated ), and wandered across a link with some interesting info I had not seen elsewhere on the Z-06 carbon fibre fenders. Rather than ignore, it, I thought I would take a minute to share - hopefully someone will find it, and the link of interest.
http://www.plasticstechnology.com/ar...200601cu1.html
), and wandered across a link with some interesting info I had not seen elsewhere on the Z-06 carbon fibre fenders. Rather than ignore, it, I thought I would take a minute to share - hopefully someone will find it, and the link of interest.http://www.plasticstechnology.com/ar...200601cu1.html
06-11-2006, 11:50 AM
#3
Melting Slicks
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Originally Posted by robvuk
Interesting
Here is more stuff no one asked for -- again, it is just some tidbits stirred up in the wake of my search for something completely different...
SMC applications include door surrounds
and door assemblies on the Corvette and
Cadillac XLR...
The Chevrolet Corvette uses LCM composites
in underbody panels, floor boards,
dash, and lower and upper plenums....
RRIM is also used for the front and
rear fenders of the Cadillac XLR, and the
fenders and front and rear fascia of the
Corvette...
http://www.autocomposites.org/autoco...ths2005aca.pdf
I may also sprinkle in some vendor info when I run across it - for instance:
ThyssenKrupp Budd makes the SMC hood - not sure what else... ah, they make the door frame and side panel as well...
Alcoa provides frame rails, suspension parts, wiring stuff, roof bow:
http://www.alcoa.com/car_truck/en/corvette_success.asp
Eurika! I have found (I think) who makes the C6 removable roof panel - the same folks who do the convert top, CTS, a wholly owned Porsche subsidary:
http://www.cartopsystems.com/english...story/2004.htm
http://www.cartopsystems.com/download/US_092903.pdf
Last edited by TrackNoob; 06-11-2006 at 02:02 PM.
06-11-2006, 12:17 PM
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Melting Slicks
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Corvette 1952-2004: A History of Materials Innovation
1952: EX-122 concept show car hand-built. Becomes forerunner of Corvette.
1953: Corvette unveiled in New York. Fiberglass chosen for production, which starts in Flint, MI, on June 30. First-year build: 300, all Polo White. Designer Zora Arkus-Duntov - who becomes Corvette chief engineer in 1968 - joins GM. Production moves to St. Louis in December.
1954: 3,400 built. Blue, red and black colors added.
1955: New small-block V-8 (195-hp) introduced (prior models powered by 150-hp 6-cyl. engines).
1956: Fiberglass removable hardtop introduced.
1957: Fuel injection, a U.S. first, debuts. Anodized aluminum trim bows on interior.
1958: Quad headlamps introduced.
1962: Aluminum radiator replaces copper.
1963: Sting Ray version introduced.
1965: Disc brakes replace drums.
1966: First sheet-molded composite (SMC) used for front body panels and hood.
1970: Plenum and instrument panel support panels switch to SMC.
1971: Rear quarter and end panels switch to SMC.
1973: Soft front bumpers to meet federal 5 mph (8 km/h) impact standard, add 35 lbs (16 kg) and 2 ins. (5 cm) to length.
1974: Duntov, who developed Corvette into high-performance car, retires.
1975: Plastic fuel-tank bladder bows.
1976: "Last" convertible built. Returns in 1986.
1978: In 25th year, 46,776 built, with starting price of $9,351.89.
1981: Assembly switches to Bowling Green, KY, from St. Louis, where last '82 was built. No '83 model, as plant shift takes place. Fiberglass-reinforced rear leaf springs debut.
1984: One-piece, lift-off SMC roof panels with massive rear glass introduced.
1986: Aluminum cylinder heads and antilock braking systems added.
1989: Airbags and 6-speed transmission introduced.
1992: 1 millionth Corvette built on July 2.
1993: Rear inner panels molded from recycled SMC, an industry first.
1994: National Corvette Museum opens in Bowling Green. Leather seats become standard for all models.
1997: All-new, fifth-generation model bows with major suspension components fabricated from aluminum. High-tech hydroformed steel used for driveshaft "tunnel." Windshield frame and IP supports switch to aluminum.
1999: Rear "tub" and front floor panels switch to lightweight balsa composite. First fixed-roof hardtop since '68 debuts.
2000: Lightweight titanium debuts for Corvette Z06 exhaust system.
2003: An estimated 35,000 models will be built, pushing 50-year output to more than 1.3 million.
2004: Carbon-fiber hood introduced for Z06, cutting weight in half.
Source: GM, Chevrolet and industry sources.
1952: EX-122 concept show car hand-built. Becomes forerunner of Corvette.
1953: Corvette unveiled in New York. Fiberglass chosen for production, which starts in Flint, MI, on June 30. First-year build: 300, all Polo White. Designer Zora Arkus-Duntov - who becomes Corvette chief engineer in 1968 - joins GM. Production moves to St. Louis in December.
1954: 3,400 built. Blue, red and black colors added.
1955: New small-block V-8 (195-hp) introduced (prior models powered by 150-hp 6-cyl. engines).
1956: Fiberglass removable hardtop introduced.
1957: Fuel injection, a U.S. first, debuts. Anodized aluminum trim bows on interior.
1958: Quad headlamps introduced.
1962: Aluminum radiator replaces copper.
1963: Sting Ray version introduced.
1965: Disc brakes replace drums.
1966: First sheet-molded composite (SMC) used for front body panels and hood.
1970: Plenum and instrument panel support panels switch to SMC.
1971: Rear quarter and end panels switch to SMC.
1973: Soft front bumpers to meet federal 5 mph (8 km/h) impact standard, add 35 lbs (16 kg) and 2 ins. (5 cm) to length.
1974: Duntov, who developed Corvette into high-performance car, retires.
1975: Plastic fuel-tank bladder bows.
1976: "Last" convertible built. Returns in 1986.
1978: In 25th year, 46,776 built, with starting price of $9,351.89.
1981: Assembly switches to Bowling Green, KY, from St. Louis, where last '82 was built. No '83 model, as plant shift takes place. Fiberglass-reinforced rear leaf springs debut.
1984: One-piece, lift-off SMC roof panels with massive rear glass introduced.
1986: Aluminum cylinder heads and antilock braking systems added.
1989: Airbags and 6-speed transmission introduced.
1992: 1 millionth Corvette built on July 2.
1993: Rear inner panels molded from recycled SMC, an industry first.
1994: National Corvette Museum opens in Bowling Green. Leather seats become standard for all models.
1997: All-new, fifth-generation model bows with major suspension components fabricated from aluminum. High-tech hydroformed steel used for driveshaft "tunnel." Windshield frame and IP supports switch to aluminum.
1999: Rear "tub" and front floor panels switch to lightweight balsa composite. First fixed-roof hardtop since '68 debuts.
2000: Lightweight titanium debuts for Corvette Z06 exhaust system.
2003: An estimated 35,000 models will be built, pushing 50-year output to more than 1.3 million.
2004: Carbon-fiber hood introduced for Z06, cutting weight in half.
Source: GM, Chevrolet and industry sources.
Last edited by TrackNoob; 06-11-2006 at 01:36 PM.
08-20-2006, 11:06 AM
#5
Melting Slicks
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If this much engineering goes into the Corvette Brake pedal, imagine how much total work and thought went into something like the LS7, or the C6 design overall...
(caution - 26 page PDF at link)
http://www.sfsa.org/tutorials/brakep...vette%20pdf%22
(caution - 26 page PDF at link)
http://www.sfsa.org/tutorials/brakep...vette%20pdf%22
08-29-2006, 06:04 PM
#6
Melting Slicks
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Here is a basic OUTLINE for the repair techniques a person needs to properly repair a twisted Z06. Be careful out there.
(PDF warning - link is to a six page PDF)
http://www.i-car.com/pdf/3tier-outlines/GEN01out.pdf
(PDF warning - link is to a six page PDF)
http://www.i-car.com/pdf/3tier-outlines/GEN01out.pdf
