Post on 07-Aug-2020
Cost-Effec*veLight-Weigh*ng
GALMSeries4thLightweightVehicle
ManufacturingSummit
JohnSellors
Ma:hewFriedman
23rdFeb2017
HotFormQuench(HFQ®)-ADisrup7veTechnologyForFormingUltra-HighStrength,Lightweight&Complex
AluminumPressings
1
Cost-Effec*veLight-Weigh*ng
Contents
Ø ExplanaFonoftheHFQ®processandtechnology
Ø ProcessbenefitsforcosteffecFveautomoFvelight-weighFng
Ø AutomoFveapplicaFons
Ø HFQ®formingofcomplexpressingsfromtailorweldedblanks
Ø IntroducFonofHFQ®intoNorthAmerica
Ø SummaryLotus Evora 400 with HFQ® technology
Cost-Effec*veLight-Weigh*ng
HFQ®OffersaVeryStrongValueProposi7on• ADisrup7veTechnologyforfastforming
complex-shapedhighstrengthaluminum
• ReducesCostthroughpartintegraFon,eliminaFonofreinforcementsandreducedtoolinginvestment
• ReduceMassby:• Replacingsteelwithaluminum• EliminaFngreinforcement• Downgaugingbyusinghigh-andultra-high
strengthgradesofaluminum
Pictureshowsdeepdrawn,highstrengthAluminumHFQ®DoorInner
• UFlizesavailablepresstechnology&alloys
AlreadyaOrac7ngsignificantinterestwithOEMsandTier1suppliers
Andiseasytoadopt:
Cost-Effec*veLight-Weigh*ng
TheHFQ®ProcessExplained
HeatBlank FormPanel QuenchinTool TemperforStrength
Solu7onisingOven AgeingOven
1 2 3 4
High-SpeedHydraulicPress High-SpeedHydraulicPress
HFQ®doesnotrequirepre-temperedmaterial.ThetemperingstagehasmovedfromtherollingmilltotheTier1.HFQ®doesNOTintroduceaddi7onalhea7ngstagestothesupplychain
Typically5-10scycleFmefromsheetenteringpresstoform&quench
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HFQ®ProcessClip-AstonMar7nAPillar
Cost-Effec*veLight-Weigh*ng
• Exchangesteelpartsforaluminumwithouttheneedtosimplifyorsplitthegeometry
BenefitsofHFQ®forAutomo7veDesign
• PartIntegra7on–lesspartsandfeweroperaFons
• Usehigh-strengthgradestoallowdowngauging(reducedweight,reducedmaterialcost)
• Removetheneedforspringback-compensa7onintoolandpartdesign
• Removereinforcementpanels(reducedweight,reducedmaterialcost,reducedprocessing)
• Replacehighstrengthextrusionswithhigh-strengthHFQ®pressings
Cost-Effec*veLight-Weigh*ng
Applica7on HighStrength HighFormability
A/B/CPillars
CantRails
FrontHeaders
ClosureInners
DoorRings
Sub-Frames
LampCans
ExteriorPanels
ASelec7onofHFQ®TypicalAutomo7veApplica7ons
CostReduc7onMassReduc7onDesignFlexibility
Cost-Effec*veLight-Weigh*ng
Suppor7ngOEMLight-Weigh7ngUsingHFQ®
MaterialsModels
SimulaFon&ToolDesign
HFQ®Manufacturing
Process
MaterialsTesFng&CharacterisaFon
ApplicaFonsEngineering(OpFmizaFonforHFQ®)
• TransfertoOEMs• SimulaFonSupport• HFQ®ToolingDesign
• SimulaFonUpdates
DefiniFveHFQ®TesFng
• IPTransfertoTiersandOEMs
• Readysupplychain• Newprocesstech
• Refinedmodels• Morealloychoice• Suppliervariants• Recycledgrades
AccreditedSupplyNetwork
OfMulFpleTiers
Choice&Cost-CompeFFve
üLowerCosts üLowerRisk üFasterDevelopment
IdeasforOpFmizaFonof
Design
Cost-Effec*veLight-Weigh*ng
TheNewAstonMar7nDB11withHFQ®Technology
Ø HFQ®ComplexAPillarReinforcementpressings–2offpercarproducedinasingleHFQ®drawopera7on
Cost-Effec*veLight-Weigh*ng
TheNewAstonMar7nDB11APillarHFQ®Pressing
Ø Achieveddrawdepthotherwiseimpossiblewithhighstrengthaluminum
MulFplebenefitsforHFQ®onthisapplicaFon:Ø Tightradii(1.5TInternal)enablesreducedbond
flangewidthandimprovedoccupantvision
Ø Highstrengthforroofcrushperformance
Ø HighformabilitytoproducedeepsecFon
Ø SingledrawoperaFon–lowinvestment
Ø DesignincludesFrontHeaderconnecFon
Ø NoSpringback
Cost-Effec*veLight-Weigh*ng
HFQ®-TailorWeldedBlank(TWB)PrototypeDoorInnerPanel
2.0mm
2.0mm2.0mm
1.5mm
ExcepFonallyhighlevelsofformabilityatlaserweldedjoints
Cost-Effec*veLight-Weigh*ng
HFQ®-TWBDoorInnerAssemblyPerformanceversusBaselineAluminumDoor
Design BeltlineS7ffness(measured
displacement)
TorsionalS7ffness(measured
displacement)
SideIntrusion
DoorInnerAssembly+
BeltlineOuterMass
MassSaving
ToolInvestment
BaselineDoorInnerassembly
<3.2mm
<8mm
207.5mm(actual)
6.067Kg(actual)
-
-
HFQ®TWB2-1.5mm
3.1mm
7.4mm
194.2mm
-1.108Kg
18.3%
-20%
ResultscourtesyofLotusEngineering
Cost-Effec*veLight-Weigh*ng
MorganAero8–FirstHFQ®VisibleSurfacePanel
Ø Complexpanelwith7ghtfeatureradius,producedinasingleHFQ®drawstage
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Introduc7onofHFQ®intoNorthAmerica
Ø Strategicpartnershipandcollabora7onwithBearDiversifiedInc.
Ø FulltechnologytransferfromImpressionTechnologiestoBDIØ Workingonmedium/highvolumeprojectsformajorOEMsinUSAto
embedHFQ®technologyonfuturevehiclesØ SignificantinterestfordifferentHFQ®
applicaFonsacrossmulFplesectors
Resources
Experience
InformaFon
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BDIGlobalFootprint
Sales Office Port Huron, Michigan
USA
Northern Stamping de Mexico Queretaro, Mexico
Chinese Partner CFA Tools – Zhejiang,
China
Bear Diversified Headquarters and NSI Operations
Cleveland, Ohio USA
NSI Welding and Coating Facility
Flint, Michigan USA
Highlands Diversified Services London, Kentucky
Cost-Effec*veLight-Weigh*ng
Summary
Ø HFQ®technologyisalreadyvalidatedonpremiumvehicles
Ø HFQ®hasmul7plebenefitsandenablesanewlevelofdesign
flexibilityforaluminumstructures
Ø Impressiontechnologiesareac7velycollabora7ngwithBDIto
introduceHFQ®intoNorthAmerica
Ø SignificantglobalinterestfrommajorautomoFveOEMs
Cost-Effec*veLight-Weigh*ng
Thankyou
AstonMarFnDB11withHFQ®Technology