Innovative materials and solutions for automotive components

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1 Innovative materials and solutions for automotive components D Aiuto Fabio CRF GML Metals Department ANFIA 28 April, 2016

2 Index Material overview Material development Twip characterization Fiat Panda front crash beam 500L Third Loading Line & 500X Third Loading Line Rear Rail Fiat 500L Rear Rail Fiat 500L U.S.A. version Rear Rail Fiat 500X Conclusions 2

3 Materials Overview FCA work very hard to reach the maximum lightweight. Following the trend of steel in FCA mass production car: STAMPATI A CALDO SU SCOCCHE FIAT Grande Punto LC 33% LC (Low Carbon) HSS+UHSS 67% Bravo PHS 4% LC 32% HSS + UHSS IF210, BH220, FeE340, FeE420, DP, TRIP PHS (Press Hardened Steel) HSS+UHSS 64% N. 500 PHS 7% % in peso LC 36% 500 L HSS+UHSS 57% Alfa Mito 955 PHS 16% LC 30% Alfa Giulietta HSS+UHSS 54% PHS 11% ALTRI 3% LC 28% HSS+UHSS 58% Nuova Panda 3

4 Jeep Renegade 4

5 Elongation (%) Material development plan 1 st steel generation 2 nd steel generation 3 st steel generation Yield Streght (MPa)

6 Major Strain Innovative material static characterization Twip steel mechanical characteristic Engineering Tensile Curve Stress [MPa] TWIP Curve Forming Limit Diagram Strain [%] Twip Steel Low Carbon Steel Minor Strain 6

7 Innovative material dynamic characterization 7

8 I.E. (mm) Innovative material Erichsen & twinning ERICHSEN TEST FEP04 FE 450 DP F FE 800 TRIP F TWIP MATERIALS BETTER FORMABILITY RESPECT TO FEP04 8

9 Innovative material welding TWIP 1000 FEP04 Good penetration NO resisting section FEP04 TWIP 1000 FEP04 NO penetration 9

10 Innovative material paintability 10

11 Innovative material hydrogen embrlittment 11

12 Front 12

13 remind front crash beam 1 twip application for automotive component Panda model PHS mm TWIP mm DP mm Hot formed Allum. TWIP Weight [kg] Cost [ ] Inv. [k ]

14 Panda Front crash beam FRONTAL POLE TEST HOT FORMED TWIP no craks 14

15 Stress [MPa] 2 FCA twip application first worldwide twip tubular & TWB application - Jeep Renegade Stress [MPa] REINFORCEMENT AL6082 T6 TWC450Y950T Thickness: 1,8mm AL6060 TWC450Y950T Thickness: 1,3mm T Strain [%] 1000 TWIP Strain [%] 15

16 500X OFFROAD Third Loading Line 16

17 Benefit of New Third Loading Line Adopting Twip Solution: Increased the off-road performance than aluminum solution Weight reduction High stability of front-end 17

18 Rear Rail Fiat 500L 18

19 Rear Rail Fiat 500L Europe Version LAC340Y410T Thickness: 2,1mm Coating: HDG DPC340Y590T Thickness: 1,6mm Coating: HDG DPC340Y590T Thickness: 2,5mm Coating: HDG FBH440Y580T Thickness: 3,0mm Coating: HDG 19

20 Rear Rail Fiat 500L U.S.A. Version In U.S.A. crash requirements are harder than Europe: No material changes respect Europe version for same component more reinforcement are add DPC340Y590T Thickness: 1,8mm Coating: HDG LAC340Y410T Thickness: 2,1mm Coating: HDG LAC340Y410T Thickness: 1,5mm Coating: HDG FBC440Y580T Thickness: 2,2mm Coating: HDG More reinforcements are add to Rear Rail 20

21 Rear Rail Fiat 500X First World Wide Platform for FCA. 21

22 Rear Rail Fiat 500X Fiat 500X Rear Rail adopts innovative Solution: Tailored Welding Blank Tailored blanks are semi-finished parts, which are typically made from sheets with different alloys, thicknesses, coatings or material properties Laser Welding Back of Rear Rail Front of Rear Rail: TWB Patent Pending PatchWork 22

23 Rear Rail Fiat 500X Rear impact Std. 301 at 80km/h main advances: High stability of rear rail and rear occupant compartment Fuel tank safety no fuel leakage PHS950Y1300T Thickness: 1,5mm Coating: AlSi PHS950Y1300T Thickness: 1,5mm Coating: AlSi PQS340Y410T Thickness: 1,6mm Coating: AlSi 23

24 Major Strain Stress [MPa] Rear Rail Fiat 500X Mechanical characteristic of PHS950Y1300T: PHS950Y1300T Longitudinal respect RD R p0.2 [MPa] R m [MPa] Elongation % min Eng True FLD at different Temperature Strain [%] T=600 C T=660 C T=720 C T=780 C Minor Strain 24

25 Differences between Old and New New Rear Rail Rear rail longer than previous model to increase the load transmission to underfloor rear during crash impact Reinforcement deleting due to PHS steel Better joining to side sill Less components Deleted OLD Deleted NEW Incorporated in rear rail element Deleted Deleted Deleted Integrated in the Patchwork 25

26 Benefit of New Rear Rail Rear Frame 500L U.S.A. Weight: 39,8 kg Rear Frame 500X Weight: 28,7 kg Weight saving = 11,1 kg In addiction to this, with lower number of component the assembly is simpler. 26

27 Conclusions Steel has the best compromise cost-performance for high volume 3 rd generation steel will be used for next car generation Aluminium use will increase for weight reduction and premium segment Composite material is useful for premium car All materials are important but every component need a specific material, related to the mission 27

28 Thanks for the attention 28

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