Following a review of future customer trends and market requirements with a large OEM customer, Red Arch (RA) embarked on a two year development program to produce a range of carbon fibre exhaust tailpipe trims; interchangeable with its existing Chrome trims and suitable for new high performance applications.  From its inception in 2012, completion and first application of the tailpipe trims was planned and successfully delivered in Qtr4 2014 .

Scope & key features:

  • Novel carbon fibre and titanium tailpipes interchangeable with current Chrome tailpipes
  • Fully warrantied including thermal resistance and aesthetic degradation
  • Suitable for small series production

 

Key Inputs (from customers):

  • Market requirements – potential markets and volumes plus future trends
  • Multiple vehicle package data

 

Key Outputs (from RA):

  • Prototype test components to support all customer testing
  • Production parts – now exceeding combined annual volumes of 25,000pa

 

 

Timing:

  • 18 months development and test program
  • 6 months first application implementation

Project Detail:

A multi-disciplined approach was adopted within the development program.  Design and simulation focused on thermal management by minimising heat conduction routes and introduction of thermal barriers between components.  This enabled heat transfer to the critical carbon zones to be minimized and weight to be optimised.  The materials group worked on various carbon fibre composites and titanium alloys to find the optimum combination capable of withstanding exhaust gas temperatures in excess of 650°C without mechanical or aesthetic degradation.  Demanding OEM standards for such properties also extend to UV protection, and 1000hours of Californian sunshine.  Other considerations included surface carbon fibre quality standards governed by production techniques and controls.  Production tooling, processes and costs were carefully considered within the design and development process.

A wide range of material tests were conducted in parallel with physical prototype rig and vehicle based testing to ensure a durable solution.

Although a number of exotic and expensive composite materials were tested and proposed, through intelligent design, simulation and an iterative process a relatively low cost carbon fibre and resin system was used to achieve the key targets. Critically for piece cost, the resin system was developed to meet the OEMs UV exposure testing without the need for any clear lacquer or coating.

A special high temperature grade of titanium was selected for stability up to 800°C.  This required a number of specialised automated welding processes to be developed particularly as some are in aesthetic areas of the trim.

During the development phase, RA designed, manufactured and trialled all necessary tooling for the project.

The table below highlights some of the tests conducted on the chosen materials.

Development-and-realisation-of-Carbon-Titanium-Tailpipe-Trims-Testing

Project Outcome:

Sales of carbon trims have far exceeded all expectations, exceeding a combined total of over 25,000 units worldwide in 2015 and still increasing month on month. Widely praised amongst the motoring press and often the focal point of press photography.

A further five projects with two separate OEMs have followed with further applications currently in development at RA.

 

Red Arch BMW M2 Exhaust and Carbon trim