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Tailored Coils – A New Process to Further Expand Tailored Applications

Mike SkilliterTWB Company L.L.C.

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AGENDA

• Automotive Market Drivers• Process Introduction

– Definition– Capability– Benefits

• Process Flexibility– Multi-Strip– Forms of Delivery– Materials

• Quality Assurance• Process Impact to Customer

– Automotive Applications– Roll Forming and Stamping

• Prototype Applications

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Customer Concerns Tailored Solutions Provide

NORTH AMERICAN MARKET DRIVERS

• Weight Reduction• Improved Fuel Economy• Reduced Emissions• Improved Crash

Worthiness• Reduced Investment• Reduced Variable Cost

• Increase in Fuel Costs• Increase in CAFE• Reduce Manufacturing

Costs• Increase Occupant Safety

Requirements• Improve Vehicle

Dynamics

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78

54

40

12 10 10 8 8 6 4

37

0

10

20

30

40

50

60

70

80

90

Front D

oor

Rear D

oor

Bodysi

de In

ner

Front R

ail - O

tr.Rear

Rail

- Mbr.

Liftgate

Whe

elhou

se - F

ront

B' Pilla

r Rein

f.

Front s

ide w

indow

Frame

A' Pilla

r/Cow

l Rein

f.Othe

r 2-

Num

ber

of A

pplic

atio

ns

Top 3 represent 63% of total applications

NORTH AMERICAN APPLICATIONS

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7870

4840

30 30 30 28

18 17 14 12 12 12 11 11 8 8 8 8 8 62 2 2

0102030405060708090

Front Door

Front Rail

- Outer

Rear Door

Bodyside In

ner

Front Rail

- Inner

B' Pillar R

einforce

me

Rear Rail

- Mem

be

A' Pillar/C

owl Rein

forcem

Wheelhouse

- Rear

Floor Pan

C' Pillar R

einforce

me

Wheelhouse

- Front

Crossmem

ber

Floor Pan Ext./T

nnel Rein

fo

Under Seat

Cross BeamLiftg

ate

Shotgun - Outer

Rocker Rein

forcemen

Rear Rail

- Cover P

latTunnel

Rail - R

einforce

men

Shotgun - Inner

Door Ring

Dash Pnl

Tunnel - Rein

forcemen

7870

4840

30 30 30 28

18 17 14 12 12 12 11 11 8 8 8 8 8 62 2 2

0102030405060708090

Front Door

Front Rail

- Outer

Rear Door

Bodyside In

ner

Front Rail

- Inner

B' Pillar R

einforce

me

Rear Rail

- Mem

be

A' Pillar/C

owl Rein

forcem

Wheelhouse

- Rear

Floor Pan

C' Pillar R

einforce

me

Wheelhouse

- Front

Crossmem

ber

Floor Pan Ext./T

nnel Rein

fo

Under Seat

Cross BeamLiftg

ate

Shotgun - Outer

Rocker Rein

forcemen

Rear Rail

- Cover P

latTunnel

Rail - R

einforce

men

Shotgun - Inner

Door Ring

Dash Pnl

Tunnel - Rein

forcemen

Top 8 represent 69% of total applications

EUROPEAN AND ASIAN APPLICATIONS

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Transfer Press Applications

Tailor Welded Blanks

Hydroform Applications Prog Die & Roll Form Parts

Tailor Welded Tubes Tailor Welded Coils

EVOLUTION OF TAILORED PRODUCTS

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AGENDA

• Automotive Market Drivers• Process Introduction

– Definition– Capability– Benefits

• Process Flexibility– Multi-Strip– Forms of Delivery– Materials

• Quality Assurance• Process Impact to Customer

– Automotive Applications– Roll Forming and Stamping

• Prototype Applications

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• Two or more COILS of steel that are continuously laser welded.

• Laser welding direction is parallel to the rolling direction• Material combinations may vary in any combination of

gage, grade, and/or coating.• Material delivered in coil for progressive die and roll

form applications

TAILORED COILS

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TAILORED COIL PROCESS

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PROCESS BENEFITS

Tailored Coil Process Advantages

• Enables Roll Forming & Progressive Die Applications

• Mass Reduction• Investment Reduction

– Tooling– Fixtures– Containers/Racks

• Variable Cost Reduction– Stamping– Assembly– Logistics

• Reduced Dimensional Variation• Fit and Finish Improvements

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AGENDA

• Automotive Market Drivers• Process Introduction

– Definition– Capability– Benefits

• Process Flexibility– Multi-Strip– Forms of Delivery– Materials

• Quality Assurance• Process Impact to Customer

– Automotive Applications– Roll Forming and Stamping

• Prototype Applications

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Tailored Coil Line Capability

• 2 or 3 coil capability• Multiple steel grades

– Mild Steel– HSLA– Dual Phase– Stainless

• Current Coil – Width - 50mm to 1200mm– Thickness - 0.6 mm to 3.0 mm

CURRENT PROCESS CAPABILITY

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Coil to Coil

Coil to Roll Form

Coil to Progressive Die

FORMS OF DELIVERY

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MATERIAL COMBINATIONS

Material IF HSLA350

DX56

DPStainless

600

DP Stainless

800

DPStainless

1000

STAINLESS STEEL

IF X X X X

X

X

X

X

X

X

HSLA X X

X

XDP

Stainless 1000

X X X

DX56 X XDP

Stainless600

X XDP

Stainless800

X X

STAINLESS STEEL X X

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AGENDA

• Automotive Market Drivers• Process Introduction

– Definition– Benefits– Capability

• Process Flexibility– Multi-Strip– Forms of Delivery– Materials

• Quality Assurance• Process Impact to Customer

– Automotive Applications– Roll Forming and Stamping

• Prototype Applications

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REAL TIME MONITORING

Integrated Systems Output Coil Mapping

No weld

Crater

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AGENDA

• Automotive Market Drivers• Process Introduction

– Definition– Benefits– Capability

• Process Flexibility– Multi-Strip– Forms of Delivery– Materials

• Quality Assurance• Process Impact to Customer

– Automotive Applications– Roll Forming and Stamping

• Prototype Applications

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Roll Form Rocker Panel Stamped Seat SupportsSteel Wheels

128 18983

177

148

274

[mm]

1,0 mm1,4 mm1,2 mm

1,2 mm1,6 mm1,2 mm

MULTIPLE APPLICATIONS

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1. Door Belt Reinforcement2. Reinforcement - Side Intrusion3. Liftgate Reinforcement

w/Hinge Supports4. Front Seat Cross Member5. Rear Seat Cross Member6. Floor Cross Member – Below

Floor Panel7. Pillar Reinforcement w/Hinge

Supports8. Roof Cross Member

POTENTIAL APPLICATIONS

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AGENDA

• Automotive Market Drivers• Process Introduction

– Definition– Benefits– Capability

• Process Flexibility– Multi-Strip– Forms of Delivery– Materials

• Quality Assurance• Process Impact to Customer

– Automotive Applications– Roll Forming and Stamping

• Prototype Applications

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2 Coil Example 3 Coil Example 3 Coil Example

t=1.0mm t=0.7mm

w=324.5 w=324.5

t=0.7mm t=1.0mm t=0.7mm

w=200mm w=269mm w=180mm

t=1.0mm t=0.7mm t=1.0mm

w=200mm w=269mm w=180mm

SIDE RAILPROGRESSIVE DIE APPLICATION

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1st application – Width of 1100 mm

Continuously welding coil lengths over 250 meters

Progressive die trials – very successful

3 welded coils processed – no forming issues

Cycle time – comparable to normal coil

ROOF BOWPROGRESSIVE DIE APPLICATION

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TAILORED COIL SUMMARY

Tailored coils provide engineered solutions for progressive die and roll form applications: – Weight Reduction– Improve Fuel Economy– Reduce Emissions– Improve Crash Worthiness– Reduce Investment– Reduce Variable Cost