BENTELER Automotive

BENTELER Automotive
Lightweight Applications Using
Aluminum Tailored Extrusions –
Sivanathan Prasoody
© BENTELER-Gruppe | Seite 1
Contents
1. 6xxx and 7xxx Series Alloys
2. Aluminum Crash Management Systems
3. Structural Solutions using Tailored Extrusions
2
6xxx and 7xxx Alloy Development
450
Typical Rp0,2 (MPa)
New! (Forge Stock)
6xxx
400
350
300
250
200
150
100
50
Benteler Cast House
0
606006
606035
606385
6005A
608250
611020
608255
611050
High quality
7xxx: Al + Zn + Mg (+ Cu)
6xxx: Al + Mg + Si (+ Cu)
Narrow casting limits
800
700
Forge Stock
Rp0,2 (MPa)
7xxx
600
500
400
300
200
100
0
700330
710850
710870
700362
710872
704670
704682
704692
3
7090
Process control
In-house competence
Integrated Optimization – Product, Process and Material
Alloy and
heat
treatment
Prototyping and
Product
verification
Extrusion
process
Prototypes
Product
design
Tool
design
Forming
process
+
Tooling
Engineering
value
chain
Manufacturing
value chain
Casting
Extrusion
4
Forming
Finishing
Monoblock Aluminum Crash Management System
+ 7xxx Monoblock (single piece design)
+ Reformed for performance and packaging
+ Integral Flange for mounting
+ No joining of crashcans
+ Function of crashcans met by tuned cross-section
Total Weight: 3,2kg
Processing of 7xxx series alloy CMS
Assembly of
towing nut
Heattreatment
Mass reduction through part integration
5
High Strength 7046 Alloy for Crash Management
Overview
strength
alloys
Festigkeitsübersicht
BAS of
7xxx7xxx
Legierungen
Rp0,2 Typisch (MPa)
+ Suitable for open profiles
+ 7046 alloy family
+ Formability similar to current 7xxx alloys
550
500
450
400
350
300
7003.30
7108.50
7108.70
7108.50
Rp0,2~ 350
MPa
1.8 kg
7003.62
7108.72
7046.70
7046.92
Rp0,2~ 500
MPa
1.3 kg
27% weight reduction
with 7046 alloy
Schematic bumper beam with
open section
6
7046.82
7046.92
High Ductility 7xxx for CMS
Design Criteria
• Dynamic Effects
• Welding Effects
• Forming Effects
• Material Effects
• Temp. Effects
7
TEB & TEx Parts/Assemblies – Another Approach to BIW
Sills
Strut Rear
Node/Joint
Firewall
Node/Joint
Floor
Side rails front
Lower Crossbeams
Doors & Closures (Inner Panel)
Upper Crossbeams
Pillars
Roof Bows
IP Carrier
Upper-front-frame
Lower Crossbeams
Strut Front
Doors & Closures (Reinforcements)
Pillars
8
TEx Parts – Extrusion to Part, Examples
Crossmember
Header
Roofbow
Brackets
9
TEB & TEx Parts/Assemblies– Process
TEB/TEx Process
•
•
•
•
•
•
•
Advantages
Proven reliable Process
Increase in Formability of precipitation
hardening Materials
• Complex Forming/Parts Integration
• Forming high Strength Alloys
• Customize Parts Properties
• Low Cost Material
Extrusion
Sawing
Optional Solutionizing
Lubrication
Multi-step forming + Trimming
Optional Cleaning and Passivation
Heat Treatment
Disadvantages
Serial Process requires specific Equipment and
Tools
• High technical effort
Increased Process- and tooling expenditure
• Dedicated Feed, Correct, Cut, Pre-Heat,
Quench, Clean, Coating Processes
required
Increased Tooling Expenditures for TEx
Forming
10
TEx Parts – Strut Tower Brace
Multistep press-forming
Front End with Tower Strut
Single piece solution
6xxx alloy
Advantages
high integrated part
low weight
excellent cost-weigh-benefit
No joining processes
Process:
2,4mm
1,5mm
load-compliant
thickness
2,0mm
Extrusion cross section
forming process with 6 steps
11
one-piece component
Multistep
Press
Forming
TEx Parts – Front
Cross-Member
Multistep press-forming
Reduced assembly
Latch Cross-Member
BMW, 5/7 series
Frontmodule components
Tolerance adjustment between
BIW and front module
Weight reduction >25% versus Steel
12
TEx Parts - Brake Pedal
Steel Press-part Concepts
Steel Welded Shell Concepts
Vehicle: AUDI A3 (MQB)
Material: S420MC
Weight: 0,79Kg
Supplier: -
Hybrid Concepts (Steel/Plastic)
Vehicle: BMW 1st Series (2012)
Material: Steel
Weight: 0,83Kg
Supplier: Cimos
BENTELER Aluminum Extrusion Concept
Extrusion
cross section
Vehicle : Lancia Delta 2009
Material: Steel + PAGF
Weight: 1,08Kg
Supplier: -
picture only symbolically
13
Weight: 0.4Kg
(50% lighter)
TEx Parts – Innovative Door Reinforcement Approach
14
TEx Parts - Lower Control Arms
Product description
Customer Benefits
•
Light weight concept and construction
•
Weight reduction up to 35%
•
Open profile with formed edges as reinforcement
•
Stiffness/Buckling increase up to 50%
•
High formability high strength aluminum alloys
6082 (T6) due to optimized process
•
No coating needed
•
Complete value chain by Benteler
(cast house / tool shop / production)
•
Competitive cost / weight ratio
•
Scalable using variable wall thickness
SOP 04.2015
weight 1,04 kg (w.o. bush)
axle load 1180 kg (D-Segment)
SOP 02.2015
weight 1,46 kg (w.o. bush)
axle load 1850 kg (E-SUV)
15
TEB – Series Assembly Example
th. 2.2
BMW Platform Hood Lock
variable thickness (6060-T6)
5xxx sheet replaced with Variable thickness
profile 6xxx
16
Thank you for your Attention
Sivanathan.Prasoody@benteler.com
© BENTELER-Gruppe | Seite 17