ThomasE mmerich Shenyang,P .R.o fC hina,S eptember1 3 ,2009

TKAS (Changchun) Tailored Blanks Ltd.

International Automotive Congress 2009

Thomas�Emmerich

Shenyang,�P.R.�of�China,�September�13th , 2009

ThyssenKrupp�Tailored�Blanks

Locations

• 4�production�plants�in�Germany

• 12�production�plants�in�other�countries

Employees

• ~�1.000�employees

Turnover�&�Volumes�(FY�2007/08)

• 570�million�€ turnover

• 54�million�blanks�delivered

• 541.000�t/a�material�processed

• 35�%�global�market�share

Start�Tailored�Blanks�

inside�of�

Thyssen Stahl�AG

1985

Future�market

Tailored�Blanks�Activities –

Production facilities ThyssenKrupp�Tailored�Blanks�In�The�World�(1)

2002

Future�market

ThyssenKrupp

(Wuhan)�Tailored�

Blanks�Ltd.�,

Wuhan,�China



2005

Future�market

TKAS�(Changchun)�

Tailored�Blanks�Ltd.,�

JV�ThyssenKrupp�and�

Ansteel,

ChangChun,�China



2006

Future�market

TKAS�(Changchun)�Steel�

Service�Center�Ltd.,�

JV�ThyssenKrupp�and�

Ansteel,�ChangChun,�

China



Future�Market

Puebla (MX)

Monroe�(MI,�USA)

Prattville (AL,�USA)

Hermosillo (MX)

Saltillo�(MX)

Wuhan (CN)

Changchun (CN)

Bursa (TR)

Olofström (S)

San�Gillio (I)

Tito�Scalo (I)

Duisburg�(D) Wolfsburg�(D)

Ostrava (CZ)




Established:�� 8th December�2004

Founders: - ThyssenKrupp�(China)�Ltd.,�55%,

- AnSteel Co.,�Ltd.,�45%

Opening:� 14th of�August�2005

Employees: 68

Equipment�*:� 1�Linear�laserwelding line,�

max.�possible�capacity�appr.�25,000ton

1�Non�linear�laserwelding and�lasercutting line,�

max.�possible�capacity�appr.�10,000ton

Coil�supplier: Tagal,�TKS,�Ansteel

*)�ThyssenKrupp�Lasertechnik

TKAS�(Changchun)�Tailored�Blanks�Ltd.


Harbin

Changchun

Shenyang

Baoding Tianjin

Beijing

TB�Market�in�North�China�(1)

Harbin: Hafei

ChangChun:

FAW VW, FAW CC, FAW Truck

Shenyang:

Brilliance, BMW Brilliance, GM

(only assembly)

Beijing: BBDC, Hysco (inhouse)

Tianjin: FAW Xiali,

FAW Toyota (currently TBs only

in Japan),

Great Wall (under construction)

Baoding:

Great Wall


Tailored blanks may consist of multiple

steel sheets of different thicknesses,

dimensions and steel grades. They can be

manufactured in a range of variants using

linear or non linear laser systems. When

the laser welding technique is used, the

sheets are assembled with a butt welding.

Tailored blank family


Overview�Raw-Material

grades

• mild�deep�drawing�grades�to�ultra�high�

strength�drawing�grades�

coatings

• hot�rolled

• cold�rolled

• hot�dip�galvanized /galvannealed

• electrolytic�galvanized

• electrolytic�zinc-nickel�galvanized

• hot�dip�aluminized�fal

gauges

• 0,6�– 3,0mm

max.�coil�width

• 2.000mm


gauge:�1.2mm

grade:�DX56D+Z

gauge:�0.7mm

grade:�DX56D+ZHigh�precision�cutting

on�a�press�or�laserHigh�speed�laser

welding�with�8kW-laser

High�quality�door�

inner�panel

Tailored�BlanksCoils Blanks

Laser�Welding�of�Tailored�Blanks


Possible�Laser�Welding�Seam�Run

Tailored�Blankswith�linear�seam�run

Tailored�Blankswith�oval�seam�run

Engineered�Blankswith�non-linear�seam�run

Tailored�Blankswith�round�seam�run


suspension�dome door�inner pillars ring�frame

cross�beam front�rail floor�panel side�panel closing�panel

Overview�of�Possible�Tailored�Blank�Applications


Technical�Advantages

Weight Parts Stability Others

Reduction

Filling�mass

Improvements

Stiffness

Corrosion�behavior

Reduction

Material

Mass�to�transport

Reduction

Press�costs

Assembling�costs

Costs�for�logistics

Tolerances

Improvements

High�resistibility�

Welding�properties

Crash�behavior


Hotform�Blanks

2007

Tailored�OrbitalsTailored�StripsPatchwork�Blanks

200620062005

Large�format

1985

Tailored�Blanks Engineered�Blanks

1991 1999

Development�of�Tailored�Products

Cost�and�weight�potential�at�example�front�rail

materialdevelopment

invest part

assembly

Tailored�Blank

TailoredBlankconceptis2,10�€ cheaperand4�% lighterthanconventionalconcept.

Total�savings

2,66

-0,68 -0,46-0,97 -1,08

-1,57-2,10

Cost�benefit�at�example�door�inner�panel

-0.09�€

€�0.20-

-0.46�€

€�0.51-

-1.84�€

€�2.24-

€�2,32-

3,05�€

Press�shop

Assembly

Investment

Development

Material

Logistics

Total�costs�benefit

Tailored�BlankTailored�Blank conventionalconventional door�inner�paneldoor�inner�panel

Calculation�basis:�225,000�vehicles�p.a.,�term:�5�years

conventional�construction

Tailored�Blank�construcion

ThyssenKrupp (Wuhan) Tailored Blanks Ltd.

Extract of�actual Tailored�Blank�application�(1)

OEM Model Parts

Ford

Ford

Ford

Ford

Ford

SGM

SGM

SGM

SGM

SGM

Focus

Mazda3

NewMondeo

S-max

VolvoS80

LaCrosse

GL8

NewRegal

Cruz

Cadillac

Doorinner,frontandrearlongitudinals

Sidemember

FrontandrearlongitudinalsExt.Fr.Sd.Memb.Rear

Ext.Fr.Sd.Memb.Rear,Rearlongitudinal

Rearlongitudinal

Frontdoorinner&Reardoorinner

Frontdoorinner

Reardoorinner

Frontdoorinner&Reardoorinner

Reardoorinner



OEM Model Parts

SGM

DPCA

DPCA

DPCA

DPCA

Royaum

Peugeot207

C2

Peugeot307

c-Triomphe

Frontdoorinner&RearDoorInner,FrontLongeron Inner&FrontLongeron OTR

FRTWheel-HouseINR

FRTWheel-HouseINR

Longeron Connect,RearLongeron,Frt.FrameandFloor

Longeron Connect,Frt Longeron,Frt.FrameandFloor



OEM Model Parts

FAWVW

FAWVW

FAWVW

FAWCC

FAWCC

FAWCC

BBDC

BBDC

FAWXiali

AudiA6L

Sagitar

Magotan

Besturn

XiaoBenTeng

Rui yi

C-class

E-class

Veizhi

SidePanelInnerLeftandRight

FrontRailLeftandRight,FloorPanel

FrontRailLeftandRight,DoorInnerLeftandRight

RearDoorandFrontDoorInner

InnerPanelFrontBodyside LeftandRight,Inner PanelBodyside ReinforcementLeftandRightInnerFrame-FrontRailLeftandRight,Reinforement

PanelofBPillarLeftandRight,RearRailLeftand

Right,InnerPanel-FrontDoorLeftandRight

FloorPanel

FloorPanel

DoorInnerLeftandRight


ThyssenKrupp�Hotform�Blanks

(1)�Production�process

Indirect�hot�forming�(two�step�process)�/�MBW® 1500��

Hot�forming�in�a

Liquid�cooled�die�

Heat�up�to�

880oC–950oCDeep�drawing

Cut�to�size�with�a�

cutting�tool�or�with�

3D�laser�cuttingSand�blasting

Heat�up�to�

880oC–950oC

Direct�hot�forming�(one�step�process)�/�MBW® 1500�+�AS�(in�use�by�ThyssenKrupp)

Hot�forming�in�a�

liquid�cooled�die�

Cut�to�size�with�a�

cutting�tool�or�with�

3D�laser�cutting


ThyssenKrupp�Hotform�Blanks�(2)

Example�B-Pillar

MBW® 1500�+AS

MHZ�340�+AS

• Combination�of�different�grades

• Application�of�one�step�process�confirmed

• Reduction�of�metal�forming�transactions�by�using�hot�forming

Hardness�profile�of�welding�seam

600

Hardness�push�down�(push�down�distance�every�0,15�mm)

Hardness�(HV01)

500

400

300

200

100

0

1 105 2015 3025 4035

after�hot�forming

before�hot�forming

For�crash-optimized�lightweight�design



Example�Side�Member

• Combination�of�different�grades

• Application�of�one�step�process�confirmed

• Reduction�of�metal�forming�

transactions�by�using�hot�forming

For�cost-optimized�lightweight�design

manganese-boron-steel

MBW® 1500�+�AS

1,20�mm

micro�alloyed�steel

MHZ�340�+�AS

1,20�mm

FR



Potential�Applications�Pulsatingsolidstatelaserinuse

• Removingofthecoatingoneachside

oftheweldgapisessential

• Newdevelopmentoftheproduction

systemcorrespondingtotheconti-

system

• Newdevelopmentofthequalitycontrol

For�lightweight�design�and�crash�standards

Bumper

Side�impact�beam

Roof�frame

B-Pillar

C-Pillar

A-Pillar

Dash�panel

Tunnel

Sill�plate

Side�member

Bumper

Frontal�crash Side�impact


Patchwork-Technologies�(1)

– Process�and�Serial�Parts

Patchwork�process

Insertion�of�local�reinforcement�by�means�of:

• spot�welding�(series)

• laser�welding�(prototypes)

• bonding�(still�under�way)

Patch


ThyssenKrupp�Patchwork�Blanks�(2)

Determination�of�possible�production�concepts

Door�inner�panel�

with�local�patches�

for�lock�reinforcement

Engine�hood�inner

with�local�patches

Engine�hood�inner�

with�local�patches

Engineered�Blank�

with�patches

Tailored�Blank�

with�patchesPatchwork�Blank�



8�quilting�seams

Ground�blank

Patch

Blank�– upper�side Blank�– lower�side



Prototypes

Big�area�remote�with�long�focal�width/CO2-laser

TKS�Window�Lid

A-pillar�/�MBW® 1500�+�AS

Reinforcement�b-pillar�left

Reinforcement�b-pillar�right

Suspension�dome�/�MBW® 1500�+�AS



Part�optimization�in�series�parts�(1)

Tailored�Blanks�potential�will�not�be�tapped�today.The�combination�of�different�grades�offer�significant�cost�and�lightweight�potentials.

0.500

Survey�– Thickness�relation�to�mechanical�characteristics

1.000 1.500 2.000 2.500 3.000 3.5000.000

0.500

1.000

1.500

2.000

2.500

Yield�strength�ratio

Thickness�ratio

Conventional�Tailored�

Blank

Lightweight�optimized�

Tailored�Blank

MHZ�260

2�mm

MHZ�260

1�mm

DX56

1,5�mm

MHZ�260

1�mm




Costs�and�weight�reduction�through�optimization�proposals

Example

0.800 1.000 1.200 1.4000.000

0.500

1.000

1.500

2.000

2.500

Thickness�ratio


Price�reduction

Weight�reduction

Actual�geometry /�optimization

H300LAD�+Z100MB

1.65�mm

H220PD�+Z100MB

2.00�mm

H220PD�+Z100MB

2.00�mm

H220PD�+Z100MB

1.00�mm

H220PD�+Z100MB

1.00�mm

H300LAD�+Z100MB

1.65�mm

Advantages�of�geometry�and�grade�optimization

• Higher�material�utilization�possible

• Reduced�Tailored�Blank�weight�about�16.9�%��

• Support�to�achieve�CO2�targets




0.800

Example�side�panel

1.000 1.200 1.400 1.600 1.800 2.0001.800

1.900

2.000

2.100

2.150

2.200


Thickness�ratio

2.050

1.950

1.850

Costs�and�weight�reduction�through�optimization�proposals�

MHZ�340

1.2�mm

HX�180

0.65�mm

Advantages�of�geometry�and�grade�optimization

Higher�material�utilization�possible;�support�to�achieve�CO2 targets

Actual�geometry

Optimization

Price�reduction

Weight�reduction


Welded�from�two�to�five�slit�strips�of�different�grade,�thickness�and/or�finish

Production�process:

• Downcoiling and�leveling�the�strips

• Weld�edges�prepared�for�high�welding�speeds

• 3�strips�laser�welded�together�in�one�production�step

• 100%�weld�checking�by�quality�assurance�systems

• Defects�marked

• Tailored�Strips�upcoiled or�cut�to�length�at�exit�from�line

Tailored�Strips are�Tailored�Blanks�direct�from�the�coil

The�new�product:�ThyssenKrupp�Tailored�Strips�(1)


ThyssenKrupp�Tailored�Strips�(2)�– production�line

DowncoilerLeveler

Edge�preparation

Pinch�roll�units

Pinch�roll�units

Strip�guide

Welding�table�1

Welding�table�2

Pinch�roll�unit

Up-

coiler


Material�combinations�in�Tailored�Strips�(3)

DC04 MHZ�340 DX56 DP-K®34/60 DP-K®45/78 DP-K®60/98 1.4301* 1.4509** 22MnB5 FB-W® 450

DC04

MHZ�340

DX56

DP-K®34/60

DP-K®45/78

DP-K®60/98

1.4301*

1.4509**

22MnB5

FB-W® 450

Carbon�steel Heat-treat- steel

Dual-phase�steel Fine�grain�steel

Stainless

successfully�

produced

*�Austenitic�stainless�steel

**�ferritic stainless�steel

development

ongoing

not�yet�

produced


1. Front�and�rear�door�left/right�

2. Anti-intrusion�reinforcement

3. Rear�roof�cross�member�and�reinforcement�

Tailgate�fastener�left/right

4. Front�seat�cross�member�left/right

5. Seat�cross�member�left/right

6. Cross�member�before�floor�panel

7. A-pillar�reinforcement�and�hinge�

reinforcement

8. Front�roof�cross�member�and�reinforcement�

left/right

Potential�uses�for�Tailored�Strips�(4)�in�auto�construction

8 3

1

2

7

4

5

6


Roof�frame�of�Tailored�Strips�(5)�using�progressive/compound�dies

Width:�238.1�mm

Thickness:�1.0�mm

Width:�476�mm


Width:�238.1�mm


Material�flow

Total�width:�952.2�mm


Seat�cross�member�made�from�Tailored�Strips�(6)

CP-W® 800

2.0�mm

CP-W® 1000

1.5�mm

CP-W® 800

2.0�mm

Stamped�seat�cross�

member

266

140 270 140


1. t�=�1.5�mm

B�=�225�mm

2. t�=�1.0�mm

B�=�350�mm

3. t�=�1.5�mm

B�=�225�mm

Progressive/compound�die:�

35�strokes/min.

Reinforcement�made�from�Tailored�Strips�(7)��using�

progressive/compound�dies,�material:�MHZ�340

1 2 3


1. t�=�1.2�mm

B�=�112�mm

2. t�=�0.7�mm

B�=�366�mm

3. t�=�1.2�mm

B�=�97�mm

Tailored�strips�(8)Exhaust�system�of�stainless�steel�Material:�stainless�steel�1.4301

Upper�and�lower�shell�separate� Upper�and�lower�shell�joined�

1

2

3


Actual�Tailored�Blank�Highlights�(1)

Inner�Panel�Bodyside Reinforcement�L�or�R

“O” part,�Xiao�Ben�Teng,�FAW-CC

Welding of

TRIP600/TRIP800


Actual�Tailored�Blank�Highlights�(2)

Inner�Panel�Front�Bodyside L�or�R

“C” part,�Xiao�Ben�Teng,�FAW-CC


Quality assurance

Online:

�Geometric Falldorf System

�Hole Detector,

�Plasma Sensor

Spot check:

�Impact Test (cup test)

��Stepnaht�(discontinuous welding line)

�Sample comparison

�Statistic visual inspection

�Root width


References (1)

Xiali�Veizhi

FCC�Besturn

FAW�VW�SagitarFAW�VW�Audi�A6L FAW�VW�Magotan

FCC�Xiao�Ben�

Teng

Daimler�

C-Class

Daimler�

E-Class

FCC�Rui yi


References (2)

Focus

Mazda�3

New�Mondeo

S-max

Volvo�S80

La�Crosse

GL8

New�Regal

Cruz

Cadillac

Royaum

Peugeot�207

C2

Peugeot�307

c-Triomphe


Thank�you�very�much�for�your�attention

感谢您的关注感谢您的关注感谢您的关注感谢您的关注

[email protected]

ThomasE mmerich Shenyang,P .R.o fC hina,S eptember1 3 ,2009

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Transcript of ThomasE mmerich Shenyang,P .R.o fC hina,S eptember1 3 ,2009