magnesium front end research and development amd 604

USAMP AMD 604 – Magnesium Front End Research and Development

This presentation does not contain any proprietary, confidential or otherwise protected information

Magnesium Front End Research and Development – Phase I

Project ID “LM008”AMD 604

1

2010 DOE Merit Review Presentation

Alan A. LuoGeneral Motors Global Research and Development

Unibody Body Front End – Steel Baseline


This presentation does not contain any proprietary, confidential or otherwise protected information 2

This material is based upon work supported by the Department of EnergyNational Energy Technology Laboratory under Award Number No.DE-FC26-02OR22910.

This report was prepared as an account of work sponsored by an agencyof the United States Government. Neither the United States Governmentnor any agency thereof, nor any of their employees, makes any warranty,express or implied, or assumes any legal liability or responsibility for theaccuracy, completeness, or usefulness of any information, apparatus,product, or process disclosed, or represents that its use would not infringeprivately owned rights. Reference herein to any specific commercialproduct, process, or service by trade name, trademark, manufacturer, orotherwise does not necessarily constitute or imply its endorsement,recommendation, or favoring by the United States Government or anyagency thereof. The views and opinions of authors expressed herein donot necessarily state or reflect those of the United States Government orany agency thereof. Such support does not constitute an endorsement bythe Department of Energy of the work or the views expressed herein.

Acknowledgement



Overview

Start: Oct. 1, 2006 End: March 31, 2010 100% complete

Improved high-volume manufacturing techniques for Mg casting, extrusion, and sheet forming

Improved high-volume manufacturing techniques for joining and corrosion protection of magnesium structures.

Improved knowledge base in Mg crashworthiness, NVH (noise, vibration and harshness), fatigue and durability

Total project funding

DOE: $1.5 M

USAMP: $2.7 M• Canada: $3M (U.S. Equiv.)

• China: $3M (U.S. Equiv.)

Funding received in FY09: $645 K

Funding for FY10: $225 K (project ended in FY10)

Timeline

Budget

Barriers/targets

OEMs: Chrysler, Ford, GM U.S. Supplier list (next slide) International Partners from China and

Canada. (slide 4)

Partners



U.S. Partner Organizations

Cosma Engineering

University of Dayton – Research Institute

IAC Corporation

Westmoreland Testing

Henkel U.S.

PPG Industries

Chemetall Oakite

MetoKote

Atotech

MacDermid

Luke Engineering

University of Michigan – Dearborn

Ohio State University

Eastern Michigan University

Contech U.S., LLC

Scientific Forming Technologies Corp.

Lehigh University

North Dakota State UniversityMississippi State UniversityMagni IndustriesKeroniteInternational Hardcoat Corp.Dow AutomotiveVisteon Inc.MNP Corp.ATF Inc.Kamax LPREMINCHitachi AmericaNorth American Die Casting Assn.Gibbs Die CastingEKK Inc.Timminco Corp.U.S. Magnesium Corp.



International Partner Organizations

Canada

CANMET(Natural Resources Canada)Auto 21 NetworkUniversity of WaterlooUniversity of Western OntarioRyerson UniversityUniversity of SherbrookeUniversity of WindsorCenterline Corp.University of TorontoNRC – Aerospace Divn.MAGNAMeridian Lightweight - Canada

China

China Magnesium Center(Ministry of Science and Technology)Tsinghua University (Beijing)Chinalco - Louyang CopperZhejiang UniversityShanghai Jiao Tong UniversityShenyang University of TechnologyXi’an University of TechnologyChongqing UniversityNortheastern UniversityInst. of Metals Research – ShenyangDalian University of TechnologyShanxi Yingguang Magnesium



Overall ObjectivesOrganize and deploy an international research and development project aimed at theadvancement of magnesium technology by a dedicated collective of researchers toward the goalof having sufficient engineering and manufacturing capabilities to exploit the full weight-reductionpotential of magnesium alloys as engineering materials for entire automotive sub-structures,thereby leading to concomitant fuel economy realizations at affordable cost, excellent vehicleperformance and with due consideration for the environment.

General TargetsMass reduction up to 60% less than steel comparator; 35% less than aluminum comparator structure Neutral or slight cost penalty compared to steel baseline Vehicle performance attributes comparable to baseline structures

FY2009 Targets Develop pertinent technologies to meet U.S. task goals Support conduct of international review meeting in Canada, May 2009 Demonstrate technology readiness required to pass project “Gate 3” (final) review Propose MFERD Phase II project to demonstrate the technologies developed in Phase I



FY2009 Milestones

Participated in the 3rd International Review Meeting in Canada on May 11-13,2009, and contributed to 2nd progress “Proceedings” (570 pages) of theinternational project released at the Canada meeting.

Passed final “Gate 3” technical reviews with international Project SteeringCommittee (including DOE representatives) in May and USAMP AMD Board ofDirectors in September, 2009.

Conducted the USAMP annual review and technology rollout on November19, 2009.

Completed “Magnesium Front End Research and Development – Phase II”project proposal and obtained approvals from USAMP and DOE in 2009/2010.



APPROACH



Unibody (BFI) Front End Design Summary(Accompanying USAMP AMD603: Magnesium Front End Design and Development)

Steel baseline design110 Parts & 99.6 kg

Mg-intensive design47 Parts & 55.3 kg

Baseline: 2008 Cadillac CTS

44.3 kg mass reduction (44.5%)63 part reduction (57.3%)

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Body-on-Frame Front End Design Summary(Accompanying USAMP AMD603: Magnesium Front End Design and Development)

Steel baseline design20 Parts & 57.1 kg

Magnesium design18 Parts & 42.9 kg

Baseline: 2009 Ford F150

14.2 kg mass reduction (24.9%)2 part reduction (10%)

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FY2009 Accomplishments - Task 1.1 Crashworthiness Generated significant tension & compression data at various strain rates for

AM30 extrusion, AZ31 sheet and AM60B die castings and initial material models for simulation

Despite the initial buckling deformation, all three Mg alloys showed pervasive fracture in crash loading, which is less desirable for automotive applications compared to Al or steel

-600

-500

-400

-300

-200

-100

0

100

200

300

400

-0.15 -0.1 -0.05 0 0.05 0.1 0.15

Engineering Strain (mm/mm)

Engi

neer

ing

Stre

ss (M

Pa)

0.00075/s-CT

0.02/s-CT

1/s-CT

0.00075/s-CT

1400/s-SG

2200/s-SG

2400/s-SG

2600/s-SG

CT-CANMETSG-Shenyang

Temperature: 294K

Magnesium Alloy AM30 Extrusion

Aluminum Alloy 5754 Extrusion

Magnesium Alloy AM30 Extrusion



FY2009 Accomplishments - Task 1.2 Noise, Vibration and Harshness (NVH) Mg has high damping capability, which can be translated into better NHV performance

in low- to mid-frequency up to 1000 Hz For high-frequency (>1000 Hz) airborne noise, a lightweight Mg panel would transmit

significantly more noise into the occupant compartment unless the acoustic frequencies could be broken up and damped

Simulation and testing suggest that proper sound package can compensate the NVH performance of a low-mass Mg panel

Dash + Sound Package 1

0

10

20

30

40

50

60

70

10 100 1000 10000 100000Frequency (Hz)

TL (d

B)

Steel Dash'Aluminium DashMagnesium DashMagnesium-Sandwich Dash

NVH Analysis with Sound

Package

1.1mm Steel2mm Mg4mm Mg

NVH simulation in low- to mid-frequency range

NVH simulation with sound packages



FY2009 Accomplishments - Task 1.3 Fatigue and Durability Completed a Round-Robin testing of 5 labs in 3 countries showing a reasonably good

agreement in test results Completed strain-life fatigue testing of extrusion alloys (AM30 & AZ31), sheet alloy

(AZ31) sheet, and casting alloys (AZ91D and AM60B) - similar fatigue results to some Al alloys

Initiated fatigue testing of Mg joints (resistance spot-welded and friction stir welded) and multi-stage fatigue modeling work - promising results

Round-Robin test results on AM30 extrusionMulti-Stage Fatigue (MSF) model correlation with experimental Strain-Life data AZ31 alloy



FY2009 Accomplishments - Task 1.4 Corrosion and Surface Finishing Completed evaluation of 14 pre-treatment processes for adhesive bonding and

corrosion resistance Developed micro arc oxidation (MAO) and a combined micro arc oxidation plus

electrophoresis (MAOE) process for corrosion protection Initiated corrosion fatigue study of Mg alloys

ASTM B117 test (20 h) of various pre-treatments

5000

10000

15000

20000

25000

30000

35000

40000

NaCl content/mass%

0.01% 0.1% 1%

cycl

es to

failu

re/N

f

σ=54.7MPa; f=1Hz; R=0.1

Corrosion fatigue life of AZ31

Corrosion test results of MAO and MAOE coated samples

Un-coated MAOEMAO



FY2009 Accomplishments - Task 1.5 Low-Cost Extrusion and Forming Developed a flow stress model and adapted DEFORM 3D for Mg extrusion simulation

using porthole dies (seam-weld) and conducted extrusion simulation Evaluated various Mg tubes for bending and warm gas-forming processes Explored microalloying (Ce, Nd & Y, etc.) to improve the mechanical properties of

AZ31, AM20, ZM21 and AZ61 alloys)

Mg extrusion simulation using DEFORM 3D Ce & Nd effect on ZM21

Stress

Pressure

Temperature

Die Setup

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

180

200

220

240

260

16

18

20

22

24

Stre

ss /

MPa

Ce / wt%

UTS YS elongation

Elon

gatio

n / %

0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8

140

160

180

200

220

240

260

16182022242628303234363840

Stre

ss /

MPa

Nd / wt%

UTS YS elongation

Elon

gatio

n / %

Bending & gas-forming



FY2009 Accomplishments - Task 1.6 Low-Cost Sheet and Forming (US contribution from USAMP AMD602)

Developed a low-cost continuous casting (CC) process in China to produce Mg sheet as thin as 1 mm

Evaluated the formability of various Mg sheet materials produced by direct-chill (DC) cast and CC processes

Developed material models (stress-temperature-strain rate relationship) for ICME activitiesDirect-chill (DC) cast and

continuous cast (CC) sheetFormability evaluationMaterial model development

DC Process CC Process



FY2009 Accomplishments - Task 1.7 High Integrity Body Casting Developed super-vacuum die castings (SVDC) with significantly improved mechanical

properties (50-60% improvement in ductility) and heat-treatability Studied the solidification process using simulation and thermal analysis Investigated the heat treatment process for SVDC castings

Super-vacuum die casting: 50-60% improvement in ductility

Heat treatment studySolidification study using thermal analysis

Alloy UTS, MPa

YS, MPa

Elongation, %

AZ91D-SVDC 230 160 4

AZ91D-HPDC 200 150 2.5

AM60B-SVDC 230 125 9

AM60B-HPDC 210 120 6

Temperature, oC

Firs

t de

riva

tive,

dT/

dt, o C/

s

-4

-3

-2

-1

0

1

2

3

4

100 200 300 400 500 600 700 800

#1

Hea

ting

#2 #3

#4

#6 #5 Cool

ing

0

5

10

15

20

25

30

0

50

100

150

200

250

300

#10 COND.2

As-cast T6 T4T6T4

MPa

YS UTS Elongation

As-cast #11 COND.1

Elon

gatio

n

Temperature, oC

Frac

tion

solid

(FS)

, %

Frac

tion

liqui

d (F

L), %

0

10

20

30

40

50

60

70

80

90

100

410 435 460 485 510 535 560 585 6100

10

20

30

40

50

60

70

80

90

100FSFL

Melting

Solidification



FY2009 Accomplishments - Task 1.8 Welding and Joining Developed the process parameters for Mg welding: MIG, laser, resistance spot and

friction stir spot welding Made significant progress in adhesive bonding and self-pierce riveting Explored Mg-to-Al joining processes: laser weld bonding and friction stir welding

MIG welding of AZ31 sheet Self-pierce rivetingLaser welding

a-3

a-4

a-5a-2

a-6a-1 a-7

Laser weld bonding of Mg to Al

Resistance spot welding

Friction stir spot welding



Future Work: Magnesium Front End Research & Development Phase II (AMD904)

Design and build demo structure which embodies attributes of a major body structure Main tasks in corrosion, fatigue and joining centered around a demo structure Continue extrusion, sheet and casting tasks to

- Make parts for the demo structure and fully integrate with ICME task- Potentially evaluate additional alloys: age-hardening alloys and reduced anisotropy

Redefine the crashworthiness and NVH tasks

Frame rail (extrusion)

Shot gun (sheet and/or casting)

Shock tower(one or more castings)

Example of “demo”



Summary As first-of-its-kind US-Canada-China collaboration, the Magnesium Front End Research

and Development Phase I Project (AMD604) has been successfully completed andclearly demonstrated the capability for an international cooperative research effortwith multiple and complex technical disciplines and targets, resulting in thedevelopment of significant enabling technologies and knowledge based formagnesium automotive applications.

Results from the companion design project (AMD603) suggest that a Mg-intensivefront end design can achieve nearly 50% mass reduction with equivalent performance(based on simulations) relative to A HIGHLY EFFICIENT STATE OF THE ART steel baselinefor the unibody architecture based upon known manufacturing technologies (e.g. diecasting, sheet forming and extrusion), and presumptions regarding joining and surfacefinishing technologies.

The Magnesium Front End Research and Development Phase II Project (AMD904) hasbeen approved and successfully launched in April, 2010, to demonstrate key enablingtechnologies developed in Phase I using a reduced “demo” structure.

magnesium front end research and development amd 604

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