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Innovative materials and solutions for automotive components
D’Aiuto Fabio
ANFIA
28 April, 2016
CRF – GML – Metals Department
Index
2
■ 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
Innovative materials and solutions for automotive components Turin, April 20, 2016
Materials Overview
3
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
LC (Low Carbon)
HSS + UHSS
IF210, BH220, FeE340,
FeE420, DP, TRIP
PHS
(Press Hardened Steel)
Grande Punto
N. 500
% in peso
PHS
4%
HSS+UHSS
64%
LC
32%
PHS
7%
HSS+UHSS
57%
LC
36%
HSS+UHSS
67%
LC
33%
Bravo
PHS
16%
HSS+UHSS
54%
LC
30%
PHS
16%
HSS+UHSS
54%
LC
30%Alfa 955Alfa Mito
Alfa Giulietta
LC
28%
HSS+UHSS
58%
PHS
11%
ALTRI
3%
Nuova Panda
500 L
Innovative materials and solutions for automotive components Turin, April 20, 2016
Jeep Renegade
4 Innovative materials and solutions for automotive components Turin, April 20, 2016
5
Material development plan
Yield Streght (MPa)
200 1200 1000 800 600 400
20
10
0
Elo
ng
ati
on
(%
)
1400
40
30
1
4
3
2 5
6
6
7
5
1 st steel generation 2 nd steel generation
3 st steel generation
Innovative materials and solutions for automotive components Turin, April 20, 2016
Innovative material – static characterization
6
Twip steel mechanical characteristic
0
100
200
300
400
500
600
700
800
900
1000
0.0 20.0 40.0 60.0 80.0
Stre
ss [
MP
a]
Strain [%]
Engineering Tensile Curve
TWIP Curve
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
-0.5 -0.4 -0.3 -0.2 -0.1 0.0 0.1 0.2 0.3 0.4 0.5
Ma
jor
Str
ain
Minor Strain
Forming Limit Diagram
Twip Steel
Low Carbon Steel
Innovative materials and solutions for automotive components Turin, April 20, 2016
7
Innovative material – dynamic characterization
Innovative materials and solutions for automotive components Turin, April 20, 2016
8
Innovative material – Erichsen & twinning
ERICHSEN TEST
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
FEP04 FE 450 DP F FE 800 TRIP F TWIP
MATERIALS
I.E
. (m
m)
BETTER FORMABILITY
RESPECT TO FEP04
Innovative materials and solutions for automotive components Turin, April 20, 2016
9
Good penetration FEP04
TWIP 1000
FEP04
TWIP 1000
FEP04
NO penetration
NO resisting section
Innovative material – welding
Innovative materials and solutions for automotive components Turin, April 20, 2016
10
Innovative material – paintability
Innovative materials and solutions for automotive components Turin, April 20, 2016
11
Innovative material – hydrogen embrlittment
Innovative materials and solutions for automotive components Turin, April 20, 2016
Front…
12 Innovative materials and solutions for automotive components Turin, April 20, 2016
… remind … front crash beam …1° twip application for automotive component – Panda model…
13
PHS1500 1.5mm
DP600 1.5mm
TWIP1000 1.4mm
Hot
formed Allum. TWIP
Weight [kg] 4.3 2.8 3.8
Cost [€] 14 20 14
Inv. [k€] 1100 550 900
Innovative materials and solutions for automotive components Turin, April 20, 2016
FRONTAL POLE TEST
HOT
FORMED
TWIP
no craks
Panda Front crash beam
Innovative materials and solutions for automotive components Turin, April 20, 2016 14
2° FCA twip application – first worldwide twip tubular & TWB application - Jeep Renegade
15
AL6060
REINFORCEMENT
AL6082 T6
0
100
200
300
400
500
600
700
800
900
1000
0 10 20 30 40 50 60
Stre
ss [
MP
a]
Strain [%]
6082 T6
TWC450Y950T
Thickness: 1,8mm
TWC450Y950T
Thickness: 1,3mm
0
100
200
300
400
500
600
700
800
900
1000
0.0 10.0 20.0 30.0 40.0 50.0 60.0
Stre
ss [
MP
a]
Strain [%]
TWIP
Innovative materials and solutions for automotive components Turin, April 20, 2016
500X OFFROAD Third Loading Line
16 Innovative materials and solutions for automotive components Turin, April 20, 2016
Benefit of New Third Loading Line
17
Adopting Twip Solution:
Increased the off-road performance than aluminum solution
Weight reduction
High stability of front-end
Innovative materials and solutions for automotive components Turin, April 20, 2016
Rear Rail Fiat 500L
18 Innovative materials and solutions for automotive components Turin, April 20, 2016
Rear Rail Fiat 500L Europe Version
19
LAC340Y410T
Thickness: 2,1mm
Coating: HDG
FBH440Y580T
Thickness: 3,0mm
Coating: HDG
DPC340Y590T
Thickness: 2,5mm
Coating: HDG
DPC340Y590T
Thickness: 1,6mm
Coating: HDG
Innovative materials and solutions for automotive components Turin, April 20, 2016
Rear Rail Fiat 500L U.S.A. Version
20
DPC340Y590T
Thickness: 1,8mm
Coating: HDG
FBC440Y580T
Thickness: 2,2mm
Coating: HDG
LAC340Y410T
Thickness: 1,5mm
Coating: HDG
LAC340Y410T
Thickness: 2,1mm
Coating: HDG
More reinforcements are add to
Rear Rail
In U.S.A. crash requirements are harder than Europe:
No material changes respect Europe version for same component …
more reinforcement are add
Innovative materials and solutions for automotive components Turin, April 20, 2016
Rear Rail Fiat 500X
21
First World Wide Platform for FCA.
Innovative materials and solutions for automotive components Turin, April 20, 2016
Rear Rail Fiat 500X
22
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
Front of Rear Rail:
Back of Rear Rail
PatchWork TWB Patent Pending
Innovative materials and solutions for automotive components Turin, April 20, 2016
Rear Rail Fiat 500X
23
PHS950Y1300T
Thickness: 1,5mm
Coating: AlSi
PQS340Y410T
Thickness: 1,6mm
Coating: AlSi
PHS950Y1300T
Thickness: 1,5mm
Coating: AlSi
Rear impact Std. 301 at 80km/h main advances:
High stability of rear rail and rear occupant compartment
Fuel tank safety – no fuel leakage
Innovative materials and solutions for automotive components Turin, April 20, 2016
Rear Rail Fiat 500X
24
Mechanical characteristic of PHS950Y1300T:
0
200
400
600
800
1000
1200
1400
1600
1800
0.0 1.0 2.0 3.0 4.0 5.0 6.0
Stre
ss [
MP
a]
Strain [%]
PHS950Y1300T
Eng
True
Rp0.2 [MPa] Rm [MPa] Elongation %
Longitudinal respect RD
950 - 1250 1300 - 1650 min. 6
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
-0.40 -0.20 0.00 0.20 0.40 0.60
Maj
or
Stra
in
Minor Strain
FLD at different Temperature
T=600°C
T=660°C
T=720°C
T=780°C
Innovative materials and solutions for automotive components Turin, April 20, 2016
Differences between Old and New New Rear Rail
25
OLD NEW
Deleted Deleted
Deleted
Incorporated
in rear rail
element
Deleted
Deleted
Integrated in
the
Patchwork
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
Innovative materials and solutions for automotive components Turin, April 20, 2016
Benefit of New Rear Rail
26
In addiction to this, with lower number of component the assembly is
simpler.
Rear Frame 500L U.S.A. Weight: 39,8 kg Rear Frame 500X Weight: 28,7 kg
Weight saving = 11,1 kg
Innovative materials and solutions for automotive components Turin, April 20, 2016
Conclusions
27
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
Innovative materials and solutions for automotive components Turin, April 20, 2016
28
Thanks for the attention
Innovative materials and solutions for automotive components Turin, April 20, 2016
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