Innovative materials and solutions for automotive components D Aiuto Fabio CRF GML Metals Department ANFIA 28 April, 2016
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
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
Jeep Renegade 4
Elongation (%) Material development plan 1 st steel generation 2 nd steel generation 3 st steel generation 40 30 5 2 20 10 6 7 1 4 6 5 3 0 200 400 600 800 1000 1200 Yield Streght (MPa) 1400 5
Major Strain Innovative material static characterization Twip steel mechanical characteristic Engineering Tensile Curve 1000 900 Stress [MPa] 800 700 600 500 400 300 200 TWIP Curve Forming Limit Diagram 0.8 0.7 0.6 100 0.5 0 0.0 20.0 40.0 60.0 80.0 Strain [%] 0.4 0.3 0.2 Twip Steel Low Carbon Steel 0.1 0.0-0.5-0.4-0.3-0.2-0.1 0.0 0.1 0.2 0.3 0.4 0.5 Minor Strain 6
Innovative material dynamic characterization 7
I.E. (mm) Innovative material Erichsen & twinning ERICHSEN TEST 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 FEP04 FE 450 DP F FE 800 TRIP F TWIP MATERIALS BETTER FORMABILITY RESPECT TO FEP04 8
Innovative material welding TWIP 1000 FEP04 Good penetration NO resisting section FEP04 TWIP 1000 FEP04 NO penetration 9
Innovative material paintability 10
Innovative material hydrogen embrlittment 11
Front 12
remind front crash beam 1 twip application for automotive component Panda model PHS1500 1.5mm TWIP1000 1.4mm DP600 1.5mm Hot formed Allum. TWIP Weight [kg] 4.3 2.8 3.8 Cost [ ] 14 20 14 Inv. [k ] 1100 550 900 13
Panda Front crash beam FRONTAL POLE TEST HOT FORMED TWIP no craks 14
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 1000 900 800 700 600 500 400 300 200 100 0 6082 T6 0 10 20 30 40 50 60 Strain [%] 1000 TWIP 900 800 700 600 500 400 300 200 100 0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 Strain [%] 15
500X OFFROAD Third Loading Line 16
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
Rear Rail Fiat 500L 18
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
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
Rear Rail Fiat 500X First World Wide Platform for FCA. 21
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
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
Major Strain Stress [MPa] Rear Rail Fiat 500X Mechanical characteristic of PHS950Y1300T: 1800 1600 1400 PHS950Y1300T Longitudinal respect RD R p0.2 [MPa] R m [MPa] Elongation % 950-1250 1300-1650 min. 6 1200 1000 800 600 400 200 Eng True FLD at different Temperature 0.70 0.60 0.50 0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 Strain [%] 0.40 0.30 0.20 0.10 T=600 C T=660 C T=720 C T=780 C 0.00-0.40-0.20 0.00 0.20 0.40 0.60 Minor Strain 24
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
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
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
Thanks for the attention 28