07 - The Application of Multiphase Steel in the Body in White
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Transcript of 07 - The Application of Multiphase Steel in the Body in White
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BMWGroup
w w w . a u t o s t e e l . o r g
The Application of Multiphase Steel
in the Body-in-White
Dr.-Ing. Markus PfestorfBMW AG
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1. Demands on materials
2. Functionality
3. Mechanical data of sheet materials
4. Material grade application
5. Forming
6. Joining
7. Summary and outlook
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BMWGroup
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Forming
•Formability•Punch force•Forming limit diagram
•Cutting•Cutting forces•Spring back
Joining
•Spot Welding•Adhesive Bonding
•MIG welding •MIG brazing•Laser welding•Riveting
Surface/Corrosion•Class A surface•Adhesive bonding
•Paint adhesion•Contact corrosion
Functionality
•Ductility during crash (Rp0,2, Rm, A80, …)
•Fatigue strength•E-Modulus (stiffness)•Weight (density)•Frequency attenuation
•Acoustics
Process: Press-Shop Body-in-White Paint Product
Demands on MaterialProcess and Product
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– EURO-NCAP, 64,4 km/h, 40 %– US-NCAP, 56,3 km/h, 100%– Pole (front), 50 km/h, middle
- IIHS low speed, 8 km/h, others,- AZT-front/rear, 15 km/h, 40%- FMVSS 201- FMVSS 208- Roof hitting test- Roll over
– JAPAN-NCAP, 55 km/h, 90°– US-LINCAP, 62 km/h– Pole (side), 29 km/h– IIHS side, 50 km/h
– BMW rear, 50 km/h, 40 %– US-FMVSS 301, 80 km/h, 70 %
FunctionalityParameters for Crash Performance
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Data for rear crash– Car weight: 1978 kg
– Barrier weight: 1365 kg
– Barrier speed: 81,7 km/h
Results:– No impact of fuel tank
– No impact in passenger cabin
– No brittle fracture of trunk lid
FunctionalityCrash Testing (BMW 6 series coupé)
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FunctionalityStiffness
BendingTorsion
f ~ cm
Inflated scale
22,8
24,8
2929,8
22
24
26
28
Hz
32
E28(1981)
E34(1988)
E39(1995)
E60(2003)
1. T
orsi
on28
20,621,8
2626,5
20
22
24
Hz
1. B
endi
ng
E28(1981)
E34(1988)
E39(1995)
E60(2003)
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Bending
Torsion
FunctionalityStiffness
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Yield strength Rp0,2
Elo
ngat
ion
at fr
actu
re A
80
Mechanical DataSheet Steel
0
5
10
15
20
25
30
35
40
%
50
0 200 400 600 800 1000 N/mm² 1400
TWIP-steel
Work hardened
Stainlesssteel
deep drawing steel
6xxx(T4)
5xxx
6xxx(T6)
Micro alloyed
IF
BakeHardening
phosphorus alloyed steel
MS
CPDP
TRIP
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0
200
400
600
800
1200
0 0,1 0,2 0,3 0,4Forming rate
Yie
ld s
treng
thR
p0,2
H400T(TRIP700)
H420LA (ZSTE420)
Nmm²
Mechanical DataComparison: H400T H420LA
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BMWGroup
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Yie
ld s
treng
th R
p0,2
0
200
400
Nmm²
800
(Supplier data)
Forming
Work hardening
Paint oven
Bake hardening
Final value of finished products
Delivery values before forming
H300LA (Micro-alloyed)
H300B (Bake-hardening steel)H300X (Dual-phase steel)
Mechanical DataWork and Bake Hardening Effects
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BMWGroup
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BMW 3 Series(SOP 1997)
Deep Draw Steels
180 N/mm²
200 -220 N/mm²
260 N/mm²
300-340 N/mm²
380-420 N/mm²
500-680 N/mm²
> 900 N/mm²
AlMg aluminum
AlSi aluminum
Plastics
Others
BMW 7 Series(SOP 2001)
BMW 5 Series(SOP 2003)
BMW 3 Series(SOP 2004)
Percentage of material (body in white incl. hang on parts)
Material Grade ApplicationIncreasing Utilization of HS Steels
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Material Grade ApplicationDetailed Case Study: BMW 3 Series
Others1%
Deep drawing steel19%
180 N/mm²19%
200 -220 N/mm²11%
260 N/mm²9%
300-340 N/mm²22%
380-420 N/mm²12%
500-800 N/mm²6%
SteelOther steelDC 03/04DX 54DX 56H180B, H180YH220B, H220YH260B, H260Y, H260LAH300B, H300LA, H300XH340LA, H340XH400TH420LAD680CDocol1000Plastics/othersPlasticsOthers
>900 N/mm²1%
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Multi-phase steel grades
Load path for frontal impact
• Deformable front• Rigid passenger
cabin
Load path for side impact
Material grade applicationImpact load path at the BMW 3 series
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BMWGroup
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Material grade application Benefit of Multiphase steel
0
50
100
150
200
kg
300
Previous 3 seriesweight: 284 kg,functionality ´98(size of new 3 series)
Wei
ght b
ody
in w
hite
Multiphase steelHigh strength steelLow strength steel < 180N/mm²
55%
45%
Weight saving by multiphase steel and high strength steel: 29 kg
0 1
Wei
ght
savi
ng + 12 kg
- 17 kg
aver
aged
min
. yie
ld
stre
ngth
: 178
N/m
m²
New 3 seriesweight: 267 kg,functionality: 2004
32%
42%
26%
Ave
rage
d m
in. y
ield
st
reng
th: 2
94 N
/mm
²
New 3 seriesweight: 296 kg,functionality: 2004
31%
69%
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H420LA (ZStE 420) H400T (TRIP700)
Severe risk of cracks Formable without cracks
Rp0,2: 420 – 560 N/mm²A80: > 17%
Rp0,2: 400 – 500 N/mm²A80: > 24%
FormingFormability
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Spring back and buckling Steps to preventspring back and buckling(required increase in package volume)
stiffeningbead
Opening of the profile by a certain angle
stiffeningbead
FormingSpring Back and Buckling
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BMWGroup
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Conventional deep drawing tool
– material: GGG70– insert not essential– not hardened interactive surface
Deep drawing tool for TRIP 700
– inserts essential– CVD coated + hardened inserts– cooling system– increased stiffness
FormingDeep Draw Tooling Considerations
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Multiphase steel:
• increase the diameter of the electrodes
• increase the electrode forces
• adaptation of the weld-ability range
5,5 mm
0 – 15°
Normal steel:
≈ 6-7 mm
0°
Multiphase steel:
t
JoiningElectrode Considerations
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JoiningAdhesive Spot Welding
Vibration test with H400T + Z100 (hot dip galvanized)
1000
10000
1,0E+04 1,0E+05 1,0E+06 1,0E+07
Number of cycles
Am
plitu
de k=4,27
2000
4000
6000
N