Steel Innovations in Hot Stamping

Paul Belanger

Director, Gestamp R&D North America

Organizational Approach Driving Innovation

R&D CentersSPAINSWEDENFRANCEGERMANYJAPANBRAZILUSCHINAINDIA

Hot Stamping Innovation History

1974 Objective: Replace cold stamping + batch hardening with forming/quenching

in one tool.

Hot Stamping Innovation History

Wear resistance

• Cutting knives

• Lawn mower knives

• Shovel blades

FIRST HARDENING LINE FIRST PRODUCTS

Hot Stamping Innovation History

Blanking

Austenizing

Forming & Quenching

Shotblasting

Key Attributes

• Formability as mild steel

• UHSS material data after hardening

• Yield strength/density ~ extruded Al

• Tight tolerances

• Good weldability

Collaboration with Luleå

University of Technology

1974-1979

• Process

• Tool

• Material

• Joining

Hot Stamping Innovation History

1983 First Automotive Product

• SAAB 9000: Side impact

beam, Front & Rear door

Hot Stamping Innovation History

Door Beam

1%

FR/RR Bumper

5%TunnelX-MBR

Sill

9%

PH 1st Gen. [Uncoated]

PH 1G

18%

28%

50%

Local

38 %

FR Rails

B-PillarA-Pillar Upper

EVOLUTION OF PHS IN TERMS OF TECHNOLOGY AND MATERIAL

Weight % of BIW possible

RR Rails

B-Pillar Local Soft Zone

Hot Stamping Innovation History

Door Beam

1%

FR/RR Bumper

5%TunnelX-MBR

Sill

9%

PH 1st Gen. [Uncoated]

PH 1G

18%

28%

50%

Local

38 %

FR Rails

B-PillarA-Pillar Upper

EVOLUTION OF PHS IN TERMS OF TECHNOLOGY AND MATERIAL

Weight % of BIW possible

PH 2nd Gen. [Corrosion protection]

PH 2G

RR Rails

B-Pillar Local Soft Zone

AlSi

Hot Stamping Innovation History

Door Beam

1%

FR/RR Bumper

5%TunnelX-MBR

Sill

9%

PH 1st Gen. [Uncoated]

PH 1G

18%

28%

50%

Local

38 %

FR Rails

B-PillarA-Pillar Upper

EVOLUTION OF PHS IN TERMS OF TECHNOLOGY AND MATERIAL

Weight % of BIW possible

PH 2nd Gen. [Corrosion protection]

PH 2G

PH 3G

PH 3rd Gen. [Softzone]

RR Rails

B-Pillar Local Soft Zone

AlSi

Hot Stamping Innovation History

Door Beam

1%

FR/RR Bumper

5%TunnelX-MBR

Sill

9%

PH 1st Gen. [Uncoated]

PH 1G

18%

28%

50%

Local

38 %

FR Rails

B-PillarA-Pillar Upper

RR Rails

B-Pillar Local Soft Zone

EVOLUTION OF PHS IN TERMS OF TECHNOLOGY AND MATERIAL

Weight % of BIW possible

PH 2nd Gen. [Corrosion protection]

PH 2G

AlSi

PH 3G

PH 3rd Gen. [Softzone]

PH 4G

PH 4th Gen. [Laser improved ]

PH 4G

PHProcess

Co-development examples

5 Technologies yielding 4 innovation products

NEW Zn Hot Stamping NEW extreme BODYSIDE

Remote Laser Seam Welding

PROCESS TECHNLOGY PRODUCT INNOVATION

In-Die Soft Zones

Flex Laser Soft Zones

3D Laser Cladding (TPP)

NEW front rail LWT

NEW rear rail LWT

NEW B Pillar LWT

1

2

3

4

5

PROCESS TECHNOLOGY PRODUCT INNOVATION

Co-development examples

5 Technologies yielding 4 innovation products

NEW Zn Hot Stamping NEW Zn BODYSIDE

Remote Laser Seam Welding

PROCESS TECHNLOGY PRODUCT INNOVATION

In-Die Soft Zones

Flex Laser Soft Zones

3D Laser Cladding (TPP)

NEW Front Rail LWT

NEW Rear Rail LWT

NEW B Pillar LWT

1

2

3

4

5

PROCESS TECHNOLOGY PRODUCT INNOVATION

Process Technology 1: Zn MSHc

Blanking Heating Stamping Laser

ALSI PROCESS EQUIPMENT (direct PHD process)

Hydraulic press

5 SPM

2-4 Blanks/stroke

Process Technology 1: Zn MSHc

Blanking Heating Stamping Laser

ALSI PROCESS EQUIPMENT (direct PHD process)

Hydraulic press

5 SPM

2-4 Blanks/stroke

Blanking Heating Stamping Shotblast

Zn PROCESS EQUIPMENT (direct MSHc, Multi-Step Hot Stamping Process*)

Technology Innovation Status:

- Zn without Microcracks ( <10µm)

- Steel modified to reduce forming start temp, enable mechanical transfer press

- Production ready ~2017-2018

910º C

Mech. transfer press

Multi-step operation

> 15 SPM1-4 Blanks/stroke

Modified 22MnB5

* Patents Pending

Process Technology 1: Zn MSHc

High speed centering & transfer system (OP05)o Transfer system

Presso Servo transfero Cycle time = 15-up SPMo Blanks per stroke = 1 – 4o 3,000k S/a

Toolingo Max OP = 4 – 5

o Thermostabilized tools

OP05 OP10 to OP50

Transfer Press

1.800 Tn

2500x4500mm

SHOTBLAST

Zn MSHc (Multi-Step Hot Stamping Process*)

* Patents Pending

Process Technology 1: Zn MSHc

Base material Similar post hot stamped mechanical properties to 22MnB5

Increased formability vs. 22MnB5 at lower temperatures

Zn-coating Offers cathodic protection

Capable for direct hot stamping process

Micro cracks < 10µm

Hot Stamping process High productivity (target cycle time 2-3”)

Furnace protective atmosphere not required

Possibility to produce complex parts including negative angles

Good weldability and savings using LWB (Ablation not required)

No Laser cutting needed

Tailored properties also possible!!

Zn Multi-Step Hot Stamping Process (MSHc*) Summary

* Patents Pending

Product Innovation 1: New Zn Bodyside

... with current multipart concept

…

… leads to TWB PH optimized Door Ring

…with Blank optimizationTWB TWB

TWB Enhanced SOF performance

Part number reduction

Simplify Assembly Complexity

Single stroke

Cost reduction (no ablation)

Mass saving

Increasing safety requirements…

4 parts assembly

1 part

Process Technology 2: Remote Laser Seam Welding

Technology: Remote Laser Seam Welding

Laser welding: With seam tracking -continuous joint

along an edge or short flange

Benefit: Mass savings (reduced flanges) while

maintaining or improving energy absorption

A-Pillar

B-Pillar

Rocker

Application opportunities…

…on BIW structural parts

Front Rails

Rear Rail

Remote laser weld

Reduced Flanges

Spotwelding

Laser Welding

Process Technology 2: Remote Laser Seam Welding

Press hardening Remote

Laser welded tube

Continuity

Remote Laser welding lines

Inner

Outer

Resistant welding

Laser

welding

• B-Pillar inner flange reduction • A-Pillar inner flange reduction

Process Technology 3: In-Die Soft Zones

• Technology: In-die partial hardening

Tailored properties on hot stamped parts

Controlled heating/cooling tool technology

Benefits:

Optional grades obtained: HT400, HT550

Application freedom: Geometry and strength

Wide areas feasibility

A-Pillar

B-Pillar

Front Rails

Application opportunities…

Process Technology 3: In-Die Soft Zones

Soft flange on A pillar to improve weld ductility

• Material grade HT400

• Oblique pole crash test on vehicle

Side crash view from upper side

NEW VOLVO XC90 Soft flange

Process Technology 4: Flex Laser Soft Zones

Technology: HT700 Flex Laser

Obtain tailored properties

Material grades obtained: HT700, HT550, HT400

Narrow areas and complex patterns feasible

Application to low thicknesses [0.8 mm]

Rivet solutions to aluminum structures

Application opportunities…

…as combination with press hardened partsFront Rails

A-PillarB-Pillar

Rear Rail

HS WheelhousesHinge Pillar

Process Technology 4: Flex Laser Soft Zones

Innovative use of the technology: Advantages

Increased bending areas energy absorption

Through higher range material

HT400 HT550 HT700

+19% abs.

+37% abs.

Energy abs.

+18%

+35%

Loading Capacity

Process Technology 4: Flex Laser Soft Zones

Innovative use of the technology: Advantages

Increased bending areas energy absorption

Through higher range material…

… combined with more flexible process

+33% abs.

+13% abs.

+9% abs.

321

Energy abs.Loading Capacity

+14%+8%

+2%

Pattern NOK

Process Technology 5: 3D Laser Cladding (TPP)

Technology: Tailored Product-Process (TPP)

Melt powdered metal with a laser

Put material at the right place for

Crash

NVH

Stiffness management

Applications

Upper B-Pillar in Side crash

A-Pillar in frontal SORB crash

Applications

Lower B-Pillar in Side crash

A-Pillar in Side Pole crash

Local

Intrusion

Ben

din

g M

om

en

t /

Fo

rce

Increase

Energy

Energy absorption

Intrusion

Ben

din

g M

om

en

t /

Fo

rce

Increase Loading capacity

Increase Stiffness

Structure sustainment (Buckle resistance)

Product Innovation 2: Front Rails

GESTAMP Current Best in Class

Press Hardening + SZ Multiband

Flex Laser Soft Zone:Decrease hat thickness1,5mm1,1mm

Performances improvement

-11% weight saving

-25% weight saving

Product Innovation

PH + SZ Multiband Progressive force

increase Controlled bending mode

3D Laser Cladding -TPP:Increase local stiffness/ buckle resistance

Controlled kinematics with local SZ Increased stiffness with same

geometry Improved failure management

GESTAMP Future Best in ClassPress Hardening + SZ Multiband & Laser applications

HT700

HT700

USIBOR+SZt. 1,1mm

USIBOR+SZt. 1,1 mm

-37% weight saving

Spot Welding Remote Laser Seam Welding:• Reduce flanges• Create continuous joint

Future Best-In-Class TechnologiesCold stamping

Baseline

Product Innovation 3: Rear Rails

GESTAMP Current Best in Class

Press Hardened + local SZ “snake”

PHS 1500 + SZt. 1,1mm PHS 1500

t. 1,0mm

HT400

HT400

PHS 1500 +SZt. 1,1mm

Product Innovation

PH + Local SZ “snake” design Controlled kinematics with local SZ

-11% weight saving

Cold stamping

Baseline

DP600t. 1,4mm

DP780t. 1,2mm

DP600t. 1,4mm

DP600t. 1,4mm

GESTAMP Future Best in ClassPress Hardened + local SZ “snake” & Laser applications

PHS 1500 +SZt. 0,8mm

PHS 1500 +SZt. 0,8 mm

PHS 1500t. 1,0mm

HT700

HT700

Controlled kinematics with local SZ Increased stiffness with same

geometry Improved failure management

-30% weight

saving

Flex Laser Soft Zone:Decrease hat thickness1.1 mm0.8 mm

3D Laser Cladding -TPP:Reduce patch size due to TPP cladding

Spot Welding Remote Laser Seam Welding:• Reduce flanges• Create continuous joint

Future Best-In-Class Technologies

Product Innovation 3: Rear Rails

20% weight saving

Stability Efficiency Repeatability Complexity

Single piece Patches not required for mode control/energy absorption

Minimal spot weld count & reduce piece cost…

Location, size, and properties of soft zones were developed using CAE

Top view

Side view

Bottom view

“Snake Design” Rear Rail - Horizontal bending control

3 1

2

1

2

3

Published by HONDA R&D America (GDIS Seminar 2015)

Co-development success example : Honda Rear rails Full vehicle Rear crash validation FMVSS301 80km/h

Co-developed by GESTAMP R&D (G-Lab)

Product Innovation 4: B-Pillar

GESTAMP Current Best in ClassCold stamping

BaselineGESTAMP Future Best in Class

PHS 1500 Mono SZ + PHS reinforcement & Laser applications

Performances improvement

-14% weight

saving

3D Laser -TPPIncrease top stiffness Improve part

bending

Flex Laser Soft flangesCreate soft material locally Improvement of failure management

3D Laser -TPP:Reduce patch due to laser cladding

Remote Laser Seam Welding:Reduce flanges

PHS 15000 Mono SZ + PHS Reinforcement

Bending mode: local

Product Innovation

HT400 Soft Zone

Cellar Design Concept

Product Innovation

• Flex laser soft flanges

• Improved failure management

-27% weight

saving

Future Best-In-Class Technologies

Product Innovation 4: B-Pillar

Co-development success example : AUDI B-Pillar weight saving and fixation concept

Smaller cross sections

Connection hot formed B Pillar to aluminum bodyside through hemming

Soft zones in flanges to join with riveting Soft zone in lower B Pillar area to ensure

smooth crash kinematics

Location, size, and properties of soft zones were developed using CAE

Product Innovation Summary

HT700 Soft Flanges Ultra thin PHS 1500,

t = 0.8mm TPP Opportunities

HS Wheelhouses

HT700 Soft ZoneHT700 Soft Flanges TPP Laser Remote

Technology

B-Pillar

A-Pillar

HT700 Soft Flanges TPP Tubular Design with Laser

Remote Technology

Rear Rails

HT700 Soft Zone TPP to increase stiffness Laser Remote Technology

TPP to increase stiffness

Deformation area

Ultra thin PHS 1500 t = 0.8mm

TPP Opportunities

Side Impact Beam

RSW Failure

RSW Failure Local Stiffness

Controlleddeformation

(All HT grades available)

(All HT grades available)

(All HT grades available)

Improve Stiffness

1 piece

Body side

TWB CladdDucti

Improve Stiffness

RSW Failure

HT700 Soft Zones HT700 Soft Flanges Ultra thin PHS 1500

t = 0.8mm TPP Opportunities

Front Rails

Controlled deformation

THANK YOUThank you