/SCT2005

SteelFuture for the Automotive IndustryEdited by Ingo von Hagen und Hans-Joachim Wieland

VDA

FVA

Table of contents

Innovative steel sheets and products for applications in vehicles 1V. Schwich, Salzgitter AG, Salzgitter, Germany,U. Jaroni, ThyssenKrupp Stahl AG, Duisburg, Germany,F. Hirschmanner, voestalpine AG, Linz, Austria

Applications for bars and rods in the automotive industry 9K. Harste, E. Wustner, Saarstahl AG, Volklingen, P. van Hullen,R. Lange, Georgsmahenhutte GmbH, Georgsmarienhutte, Germany

Safety systems and concepts -today and in the future 18J. Kohler representing Schoneburg, DaimlerChrysler AG,Sindelfingen, Germany

Steel solutions to environmental challenges in automotivesupply chains 20D. Milbourn, J. Hunt, Corns Engineering Steels, Rotherham, England

Body structure I

Advanced steel body concepts for automotive lightweight design 28H.-G. Herrmann, DaimlerChrysler AG, Research Body andPowertrain, RBP, Stuttgart, Germany

Structural requirements and material selection in body development 32S. Gloger, T. Wanke, International Technical DevelopmentCenter (ITDC), Adam Opel AG, Russelsheim, Germany

The modular and flexible body concept of the NewSteelBody® 36O. Hoffmann, L Patberg, A. Gruneklee, ThyssenKrupp Stahl AG,Division Auto, Duisburg, Germany

Different modular BIW-concepts for truck cabs in steel 44R. Schulz, Wilhelm Karmann GmbH, Osnabriick, A. Kroff,Salzgitter Mannesmann Forschung GmbH, Salzgitter, Germany

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Body structure II

Hot dip galvanised dual phase steels for automotive applications 49S. Paul, U. Eggers, V. Flaxa, C. Fritzsche, T. Koll, SalzgitterMannesmann Forschung GmbH, Salzgitter, A, Georgiew,Salzgitter Flachstahl GmbH, Salzgitter, Germany

Cold-rolled complex-phase steels: AHSS materialwith remarkable properties 57T. Hebesberger, A. Pichler, C. Walch, M. Blaimschein,voestalpine Stahl GmbH, Linz, K. Spiradek-Hahn,ARC Seibersdorf research GmbH, Seibersdorf, Austria

Ultra high strength steel sheets for bodies, reinforcement parts,and seat frame parts of automobile 65H. Kawabe, K. Kawamura, K. Hasegawa, Y. Tanaka,JFE Steel corporation, Hiroshima, Y. Hosoya,JFE Steel corporation, Chiba, Japan

Properties of austenitic high manganese steels with inducedplasticity (L-IP® steels) 73H. Hofmann, S. Goklu, H. Richter, ThyssenKrupp Stahl AG, Dortmund,M. Menne, ThyssenKrupp Stahl AG, Duisburg, Germany

Longproducts I

Cold-formed shapes for high performance automotive components 81S. Engineer, EZM Edelstahlzieherei Mark, Wetter, Germany

Production of stress relieved steel bars for racks in steering systems 88N.Vieweg, A. Zoscher, Stahl Judenburg GmbH, Judenburg,H.Schollnhammer, G. Wolf, voestalpine Stahl Donawitz GmbH, Austria

Production and quality assurance of bright steel productsfor high performance components in fuel injection systems 96P. JanRen, F. Bodenstein, Mittal Steel Ruhrort GmbH, Duisburg,S. Engineer, EZM Edelstahlzieherei Mark, Wetter, Germany

Innovative process chains for crankshafts and gears 104B. Denkena, J. C. Becker, N. Kramer, F. Catoni,Institute of Production Engineering and Machine Tools (IFW),Hannover University, Garbsen, Germany

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Longproducts II

New microalloyed steels for heavy duty forgings in cars and trucks 112J. Arndt, CDP Bharat Forge GmbH, Ennepetal, Germany

Development of an "as forged" microalloyed steel with hightorsional fatigue strength for truck crankshafts 120M.-T Perrot-Simonetta, M. Confente, Mittal Steel EuropeR &D, Amneville, France, H. Peipe, W. Hamann, ThyssenKruppGerlach GmbH (Groupe TKA), Homburg, Germany, X. Olagne,J.-D. Bertel, ThyssenKrupp Mavilor (Groupe TKA), L'Horme, France,P. JanBen, L Wishardt, Mittal Steel Rurhrort, Duisburg, Germany

High performance specific steels for engines of the future 128P. Daguier, P. Dierickx, O. Finot, Ascometal,Hagondange, Cedex, France

Management of defects for automotive components 137S. Engineer, EZM Edelstahlzieherei Mark GmbH, R. Lange,Georgsmarienhutte GmbH, H.-J. Wieland, Steel Institute VDEh,Germany

Cold formed steel sheets

Influences on the part quality in conventional deep drawingprocesses 144B.-A. Behrens, J.-W. Yun, C. Schaffner, C. Sunderkotter,Institute of Metal Forming and Metal Forming Machine Tools,University of Hanover, Garbsen, M. Kroning, I. Altpeter, M. Kopp,Fraunhofer Institute Nondestructive Testing,University Saarbrucken, Saarbriicken, Germany

High pressure sheet metal forming of large scale body structures 152M. Trompeter, R. Krux, W. Homberg, M. Kleiner Institute of FormingTechnology and Lightweight Construction (IUL),University of Dortmund, Dortmund, Germany

Press shop equipment for sheet part forming 160W. Neubert, V. Thorns, Technische Universitat Dresden,Dresden, Germany

Development of a crash management bumper system out ofadvanced high strenght taylored rolled steel 168C.-M. Honsel, A. Koritsch, Magma Cosma Europe, Sailauf, Germany

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Hot formed steel sheets

Press hardening steel (PHS): a new coating and process technology 172J. Faderl, voestalpine Stahl Linz GmbH, Linz, Austria,R. Vehof, Polynorm N. V., GM Bunschoten, Netherlands

Determination of the heat transfer during hot stamping 179M. Geiger, M. Merklein, C. Hoff, LFT, Erlangen, Germany

Forming of heat treatable-high strength steel sheets atelevated temperature 187H. Livatyali, Istanbul Technical University, Istanbul, M. Terziakin,Metalform Engineering. Ltd., Istanbul Technical University,Istanbul, Turkey

Improved formability of ultra high strength steels throughlocal heat treatment 196B. Carlsson, L Olsson, SSAB TunnplatAB, Sweden

Massive forming

The potential of massive formed parts - Unrivalled safetyand innovation 204H. U. Volz, Industrieverband Massivumformung e. V.,Hagen, Germany

New developments in bulk forming of power train components ofenhanced performance characteristics 213B. Lorenz, R. Glass, H. Hartwig, Fraunhofer Institut Werkzeug-maschinen und Umformtechnik, Chemnitz, Germany

Comparison between hobbed & precision forged helical gearsfor automobile manual transaxle - on the prospect of form, precision,material specification and production cost 221M. Ooka, Y. Kawasaki, H. Tsujimoto, T. Hoguchi, S. Yamazaki,M. Yoshinaga, O-oka Co., Toyota, Geust Prof. ChubuUniversity, Kasugai, I. Moriwaki, Institute of Technology, Kyoto,C. Kagaya, Chubu University, Kasugai, Japan

Ductile and yet solid? - Recent steel development in a classicconflict of targets 229W. Wosting, Winkelmann Dynaform Technik, Ahlen, Germany

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Case hardening of steel bars

Innovative heat treating technologies in the automotive industry 237K. Loser, ALD Vacuum Technologies GmbH, Hanau, Germany

Temperature - the key to optimize cost and result in carburizingvehicle driveline parts 245S. Hock, J. Kleff, I. Kellermann and M. Schulz, ZF Friedrichs-hafen AG, Friedrichshafen, Germany

Microalloying in case hardening steels - a challenge for thelean production of gears 256S. Trute, W. Bleck, Department of Ferrous Metallurgy,RWTH Aachen University, Aachen, F. Hippenstiel,Edelstahlwerke Buderus AG, Wetzlar, C. Klinkenberg,Niobium Products Company GmbH, Dusseldorf, Germany

Tailored solutions in case hardening steels for highpressuregas quenching 264F. Hippenstiel, R. Caspari, Edelstahlwerke Buderus AG,Wetzlar, Germany

Tailored products I

Lightweight components through custom rollforming in theautomotive industry 272G. Lengauer, voestalpine Krems GmbH, Krems, Austria

Improvement of hydroforming processes using tailoredsemi-finished tubes 279R. Gobel, S. Chatti, W. Homberg, M. Kleiner, R. Shankar,Institute of Forming Technology and Lightweight Construction,University of Dortmund, Dortmund, Germany

Third generation of Thyssen tailored tubes - a newcategory of tubular products 287T. Flehmig, M. Bruggenbrock, M. Kibben, S. Schwenecke,ThyssenKrupp Stahl, Duisburg, Germany

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Tailored products II

Application of advanced high strength hot-rolled steelsto automotive chassis parts 299Y.-R. Cho, H.G. Kim, KG. Chin, POSCO, W.S. Lee, Hyundai MOBIS,Yongin, Korea, T. W. Kwon, Hwashin Co., Ltd, Yeongcheon, Korea

Non vacuum electron beam welding of zinc coatedhigh-strength steels 307F.-W. Bach, A. Beniyash, K. Lau, R. Versemann,Institute of Materials Science, University of Hanover,Hannover, Germany

Development of non-linear TWB parts 315J. Lee, C. S. Yoon, J. D. Lim, Hyundai Motor Company & Kia MotorsCorporation, Korea, H.-C. Park, Hyundai Hysco, Korea

Are light weight structures still affordable? - Cost modelfor tailored products 322D. Schwarz, L. Korves, ThyssenKrupp Tailored Blanks GmbH,Duisburg, T. Floth, ThyssenKrupp Stahl AG, Duisburg, Germany

Springs

Design and finite element analysis of the spring elementsfor automotive applications 330V. Kobelev, Technology Center, Muhr und Bender KG,Attendorn, Germany

High-strength steel in coil spring production 341H. Dziemballa, L. Manke, ThyssenKrupp Federn GmbH,Hagen, Germany

European supply chain for valve springs 349G. Barthold, Scherdel GmbH, Marktredwitz, Germany,D. Thureborn, M. Hallberg, Haldex Garphyttan AB,Garphyttan, Sweden, P. Janfien, MittalSteel Ruhrort GmbH/Mittal Steel Hochfeld GmbH, Germany

Evaluation of the cleanness of SiCr-spring steels forsuspension springs 357P. Valentin, A. Blasius, C. Bruch, Saarstahl AG,Volklingen, Germany

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Joining techniques and fasteners

Joining trends in automotive industry 367K.-D. Debschutz, DaimlerChrysler AG, Research and Technology,Ulm, Germany

Microalloyed steels for non heat treated ball studs and pins 374U. Urlau, S. Hasler, Moos Stahl AG, Emmenbrucke, Switzerland,J. Kruse, ZF Lemforder Fahrwerktechnik GmbH & Co. KG,Lemforde, Germany

Stainless steel fasteners - current status andrecent developments 384A. van Bennekom, A. Bauk and F. Wilke, EdelstahlwerkeSudwestfalen, Siegen, Germany.

Surface engineering I

Processing hot-dip galvanized AHSS grades:a challenging task 393A. Pichler, T. Hebesberger, E. Tragl, S. Traint, J. Faderl, G. Angeli,K. Kosters, voestalpine Stahl GmbH, Linz, Austria

High temperature galvanising 401T. Wesselow, SVG Siegener Verzinkerei GmbH, Siegen Germany

Analysis of the surface oxides on the steels whichcontrol phosphatability 409M. Nomura, I. Hashimoto, Kobe Steel, Ltd., Kobe, M. Kamura,S. Kozuma, Y. Omiya, Kobe Steel, Ltd., Kakogawa, Japan

Tailored steel strip coatings for modern car body andcorrosion concepts 416N. Samann, I. Rogner, S. Konig DOC Dortmunder OberflachenCentrum, Dortmund, Germany

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Surface engineering II

Status of corrosions protection primers for theautomotive industry 424P. Hoffmann-Loser, Adam Opel AG, Russelsheim, Germany,A. Schnell, DaimlerChrysler, Sindelfingen, Germany,K.-H. Stellnberger, F. M. Androsch, voestalpine Stahl,Linz, Austria, T. Reier, SZMF, Salzgitter, Germany,J. Lewandowski, ThyssenKrupp Stahl, Duisburg, Germany,C. Filthaut, DOC Dortmunder OberflachenCentrum, Dortmund,Germany, A. Besseyrias, Arcelor, Florange, France, C. Dane,Corns, Ijmuiden, The Netherlands, G. Steinbeck,Steel Institute VDEh, Dusseldorf, Germany

Pre-painted steel sheet - a qualified material forautomotive series production? 432B. StrauB, voestalpine Stahl GmbH, Linz, Austria,I. Rogner, DOC Dortmunder Oberflachencentrum, Dortmund, Germany

Long-wave textural components in sheet surfacesand their influence on painting results 440O. Deutscher, Betriebsforschungsinstitut (BFI) VDEh-lnstitutfur Angewandte Forschung GmbH, Dusseldorf, Germany

State-of-the-art surface inspection technology with parsytec 5i 448A. Jordan, M. Karlowitsch, Parsytec AG, Aachen, Germany

Microalloying concepts

The role of niobium in lightweight vehicle construction 456H. Mohrbacher, C. Klinkenberg, Niobium Products Company GmbH,Dusseldorf, Germany

Tailor-made steels for applications in commercialvehicle construction 464H. Luecken, B. Ehrhardt, H.-J.Tschersich, T. Niessen, H.-J. KaiserThyssenKrupp Stahl AG, Duisburg, Germany

Development of high strength deep drawing coldrolled steel sheets (AIF340) for automobiles 472X. Shi, AnGang Technique Center, AnGang, China

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Effect of niobium addition on mechanical properties of hotrolled TRIP-aided steel sheets for automotive application 473S. Hashimoto, CBMM Asia Co. Ltd., Tokyo, S. Ikeda, Kobe Steel Ltd.,Kobe, K.-i. Sugimoto, Shinshu University, Nagano, S. Miyake,Kobelco Research Institute, Inc. Kakogawa, Japan

Material parameters I

Determination of input data for numerical design of auto body sheetsteels: a joint project of the steel and automotive industries 481G. Steinbeck, Steel Institute VDEh, Dusseldorf, W. Bleck,Department for Ferrous Metallurgy, RWTH Aachen University,Aachen, C.-P. Bork, Federal Institute for Materials Research andTesting, Berlin, T. Evertz, Salzgitter Mannesmann Forschung GmbH,Salzgitter, A. Frehn, Benteler Automotive GmbH, Paderborn,R. Masendorf, Institute for Plant Engineering and Fatigue Analysis,Technical University of Clausthal, Clausthal-Zellerfeld, C. M. Sonsino,Fraunhofer-lnstitute for Structural Durability and System Reliability LBF,Darmstadt, Germany

Bake-hardening properties of TRIP and dual-phase steels 489W. Bleck, S. Bruhl, Department of Ferrous Metallurgy, RWTH AachenUniversity, Aachen, T.Gerber, Centre of Material Excellence,ThyssenKrupp Stahl AG, Dortmund, Germany

Using the bake hardening effect of hot rolled multiphase steelsfor weight optimised components 497H. Palkowski, T. Anke, Institut fur Metallurgie (MET), TU Clausthal,Clausthal-Zellerfeld, Germany

Material parameters II

Modern methods of material characterization during thedevelopment of new steels for automotive application 505M. Borsutzki, D. Mattissen, T. W. Schaumann, H.-J. Sieg,ThyssenKrupp Stahl AG, Duisburg, Germany

New techniques of the mechanical properties assessmentfor advanced high strength steel (AHSS) in automobile 516J. Fang, Baoshan Iron & Steel Co., Ltd., Baosteel, Shanghai, China

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Spot welding of high strength steel in automobile production 524B. Kalinowski, H. Kantereit, Adam Opel AG, Russelsheim, Germany

Microstructure - mechanical properties relationship ofdeep drawn pearlitic wires 531/. de Curiere, P. Lesoeurs, E. Depraetere, Manufacture Michelin,Clermont-Ferrand, France

Crash

High strain rate tensile testing of modern car body steels 539P. Larour, A. Baumer, W. Bleck, Department of Ferrous Metallurgy,RWTH Aachen University, Aachen, Germany

Influence of material model on crash simulations 547C. ten Horn, S. Carless, I. van Stijn, Corns ResearchDevelopment & Technology, Umuiden, The Netherlands

On modelling of the strain rate effect in automotive steels 555J. Larsson, SSAB Swedish Steel, Borlange, Sweden

Poster exhibition

Tailor welded blanks in high strength steel 563Q. Yan, Baoshan Iron and Steel Corp., Shanghai, China

Semi-hot stamping as an alternative to hot press forming 564T. Heller, F.-J. Lenze, M. Ruthenberg, ThyssenKrupp Stahl AG,Duisburg, Germany

New Multiphase-Bainitic-Steels with improved properties 565S. Detroy, D. Ponge, D. Raabe, Max-Planck-lnstitut furEisenforschung GmbH, Dusseldorf, Germany

Improvement of mechanical properties of spring steels throughapplication of thermomechanical treatment 566A. Ardehali Barani, D. Ponge, R. Kaspar, Max-Planck-lnstitutfur Eisenforschung GmbH, Dusseldorf, Germany

Modern carburising treatments and their influence on theendurance limit 567H. Bomas, S. Laue in cooperation with Fachgebiet Technische

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Mechanik - Strukturmechanik of University Bremen,Stiftung Institut fur Werkstofftechnik, Bremen, Germany

Effect of parameter treatment on intermetallic compoundsobtained by galvanization 568Y. Benarioua, Departement de Genie Mecanique,Universite M'sila - Algerie

The need of web based application for formability analysis ofautomobile compenent 569R. S. Hingole, V. M. Mandedkar, Mechanical EngineeringDepartement, Amruptvahini College of Engineering,Sangamner, dist. Ahmednagar, Maharashtra, India

State of the art of steel thixoforming 570W. Bleck, W. Puttgen, Department of Ferrous Metallurgy,RWTH Aachen University, Germany

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