thomase mmerich shenyang,p .r.o fc hina,s eptember1 3 ,2009
TRANSCRIPT
TKAS (Changchun) Tailored Blanks Ltd.
International Automotive Congress 2009
Thomas�Emmerich
Shenyang,�P.R.�of�China,�September�13th , 2009
ThyssenKrupp�Tailored�Blanks
Locations
• 4�production�plants�in�Germany
• 12�production�plants�in�other�countries
Employees
• ~�1.000�employees
Turnover�&�Volumes�(FY�2007/08)
• 570�million�€ turnover
• 54�million�blanks�delivered
• 541.000�t/a�material�processed
• 35�%�global�market�share
Start�Tailored�Blanks�
inside�of�
Thyssen Stahl�AG
1985
Future�market
Tailored�Blanks�Activities –
Production facilities ThyssenKrupp�Tailored�Blanks�In�The�World�(1)
2002
Future�market
ThyssenKrupp
(Wuhan)�Tailored�
Blanks�Ltd.�,
Wuhan,�China
Tailored�Blanks�Activities –
Production facilities ThyssenKrupp�Tailored�Blanks�In�The�World�(2)
2005
Future�market
TKAS�(Changchun)�
Tailored�Blanks�Ltd.,�
JV�ThyssenKrupp�and�
Ansteel,
ChangChun,�China
Tailored�Blanks�Activities –
Production facilities ThyssenKrupp�Tailored�Blanks�In�The�World�(3)
2006
Future�market
TKAS�(Changchun)�Steel�
Service�Center�Ltd.,�
JV�ThyssenKrupp�and�
Ansteel,�ChangChun,�
China
Tailored�Blanks�Activities –
Production facilities ThyssenKrupp�Tailored�Blanks�In�The�World�(4)
Future�Market
Puebla (MX)
Monroe�(MI,�USA)
Prattville (AL,�USA)
Hermosillo (MX)
Saltillo�(MX)
Wuhan (CN)
Changchun (CN)
Bursa (TR)
Olofström (S)
San�Gillio (I)
Tito�Scalo (I)
Duisburg�(D) Wolfsburg�(D)
Ostrava (CZ)
Tailored�Blanks�Activities –
Production facilities ThyssenKrupp�Tailored�Blanks�In�The�World�(5)
TKAS (Changchun) Tailored Blanks Ltd.
TKAS (Changchun) Tailored Blanks Ltd.
TKAS (Changchun) Tailored Blanks Ltd.
Established:�� 8th December�2004
Founders: - ThyssenKrupp�(China)�Ltd.,�55%,
- AnSteel Co.,�Ltd.,�45%
Opening:� 14th of�August�2005
Employees: 68
Equipment�*:� 1�Linear�laserwelding line,�
max.�possible�capacity�appr.�25,000ton
1�Non�linear�laserwelding and�lasercutting line,�
max.�possible�capacity�appr.�10,000ton
Coil�supplier: Tagal,�TKS,�Ansteel
*)�ThyssenKrupp�Lasertechnik
TKAS�(Changchun)�Tailored�Blanks�Ltd.
TKAS (Changchun) Tailored Blanks Ltd.
Harbin
Changchun
Shenyang
Baoding Tianjin
Beijing
TB�Market�in�North�China�(1)
Harbin: Hafei
ChangChun:
FAW VW, FAW CC, FAW Truck
Shenyang:
Brilliance, BMW Brilliance, GM
(only assembly)
Beijing: BBDC, Hysco (inhouse)
Tianjin: FAW Xiali,
FAW Toyota (currently TBs only
in Japan),
Great Wall (under construction)
Baoding:
Great Wall
TKAS (Changchun) Tailored Blanks Ltd.
Tailored blanks may consist of multiple
steel sheets of different thicknesses,
dimensions and steel grades. They can be
manufactured in a range of variants using
linear or non linear laser systems. When
the laser welding technique is used, the
sheets are assembled with a butt welding.
Tailored blank family
TKAS (Changchun) Tailored Blanks Ltd.
Overview�Raw-Material
grades
• mild�deep�drawing�grades�to�ultra�high�
strength�drawing�grades�
coatings
• hot�rolled
• cold�rolled
• hot�dip�galvanized /galvannealed
• electrolytic�galvanized
• electrolytic�zinc-nickel�galvanized
• hot�dip�aluminized�fal
gauges
• 0,6�– 3,0mm
max.�coil�width
• 2.000mm
TKAS (Changchun) Tailored Blanks Ltd.
gauge:�1.2mm
grade:�DX56D+Z
gauge:�0.7mm
grade:�DX56D+ZHigh�precision�cutting
on�a�press�or�laserHigh�speed�laser
welding�with�8kW-laser
High�quality�door�
inner�panel
Tailored�BlanksCoils Blanks
Laser�Welding�of�Tailored�Blanks
TKAS (Changchun) Tailored Blanks Ltd.
Possible�Laser�Welding�Seam�Run
Tailored�Blankswith�linear�seam�run
Tailored�Blankswith�oval�seam�run
Engineered�Blankswith�non-linear�seam�run
Tailored�Blankswith�round�seam�run
TKAS (Changchun) Tailored Blanks Ltd.
suspension�dome door�inner pillars ring�frame
cross�beam front�rail floor�panel side�panel closing�panel
Overview�of�Possible�Tailored�Blank�Applications
TKAS (Changchun) Tailored Blanks Ltd.
Technical�Advantages
Weight Parts Stability Others
Reduction
Filling�mass
Improvements
Stiffness
Corrosion�behavior
Reduction
Material
Mass�to�transport
Reduction
Press�costs
Assembling�costs
Costs�for�logistics
Tolerances
Improvements
High�resistibility�
Welding�properties
Crash�behavior
TKAS (Changchun) Tailored Blanks Ltd.
Hotform�Blanks
2007
Tailored�OrbitalsTailored�StripsPatchwork�Blanks
200620062005
Large�format
1985
Tailored�Blanks Engineered�Blanks
1991 1999
Development�of�Tailored�Products
Cost�and�weight�potential�at�example�front�rail
materialdevelopment
invest part
assembly
Tailored�Blank
TailoredBlankconceptis2,10�€ cheaperand4�% lighterthanconventionalconcept.
Total�savings
2,66
-0,68 -0,46-0,97 -1,08
-1,57-2,10
Cost�benefit�at�example�door�inner�panel
-0.09�€
€�0.20-
-0.46�€
€�0.51-
-1.84�€
€�2.24-
€�2,32-
3,05�€
Press�shop
Assembly
Investment
Development
Material
Logistics
Total�costs�benefit
Tailored�BlankTailored�Blank conventionalconventional door�inner�paneldoor�inner�panel
Calculation�basis:�225,000�vehicles�p.a.,�term:�5�years
conventional�construction
Tailored�Blank�construcion
ThyssenKrupp (Wuhan) Tailored Blanks Ltd.
Extract of�actual Tailored�Blank�application�(1)
OEM Model Parts
Ford
Ford
Ford
Ford
Ford
SGM
SGM
SGM
SGM
SGM
Focus
Mazda3
NewMondeo
S-max
VolvoS80
LaCrosse
GL8
NewRegal
Cruz
Cadillac
Doorinner,frontandrearlongitudinals
Sidemember
FrontandrearlongitudinalsExt.Fr.Sd.Memb.Rear
Ext.Fr.Sd.Memb.Rear,Rearlongitudinal
Rearlongitudinal
Frontdoorinner&Reardoorinner
Frontdoorinner
Reardoorinner
Frontdoorinner&Reardoorinner
Reardoorinner
ThyssenKrupp (Wuhan) Tailored Blanks Ltd.
Extract of�actual Tailored�Blank�application�(2)
OEM Model Parts
SGM
DPCA
DPCA
DPCA
DPCA
Royaum
Peugeot207
C2
Peugeot307
c-Triomphe
Frontdoorinner&RearDoorInner,FrontLongeron Inner&FrontLongeron OTR
FRTWheel-HouseINR
FRTWheel-HouseINR
Longeron Connect,RearLongeron,Frt.FrameandFloor
Longeron Connect,Frt Longeron,Frt.FrameandFloor
TKAS (Changchun) Tailored Blanks Ltd.
Extract of�actual Tailored�Blank�application�(3)
OEM Model Parts
FAWVW
FAWVW
FAWVW
FAWCC
FAWCC
FAWCC
BBDC
BBDC
FAWXiali
AudiA6L
Sagitar
Magotan
Besturn
XiaoBenTeng
Rui yi
C-class
E-class
Veizhi
SidePanelInnerLeftandRight
FrontRailLeftandRight,FloorPanel
FrontRailLeftandRight,DoorInnerLeftandRight
RearDoorandFrontDoorInner
InnerPanelFrontBodyside LeftandRight,Inner PanelBodyside ReinforcementLeftandRightInnerFrame-FrontRailLeftandRight,Reinforement
PanelofBPillarLeftandRight,RearRailLeftand
Right,InnerPanel-FrontDoorLeftandRight
FloorPanel
FloorPanel
DoorInnerLeftandRight
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Hotform�Blanks
(1)�Production�process
Indirect�hot�forming�(two�step�process)�/�MBW® 1500��
Hot�forming�in�a
Liquid�cooled�die�
Heat�up�to�
880oC–950oCDeep�drawing
Cut�to�size�with�a�
cutting�tool�or�with�
3D�laser�cuttingSand�blasting
Heat�up�to�
880oC–950oC
Direct�hot�forming�(one�step�process)�/�MBW® 1500�+�AS�(in�use�by�ThyssenKrupp)
Hot�forming�in�a�
liquid�cooled�die�
Cut�to�size�with�a�
cutting�tool�or�with�
3D�laser�cutting
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Hotform�Blanks�(2)
Example�B-Pillar
MBW® 1500�+AS
MHZ�340�+AS
• Combination�of�different�grades
• Application�of�one�step�process�confirmed
• Reduction�of�metal�forming�transactions�by�using�hot�forming
Hardness�profile�of�welding�seam
600
Hardness�push�down�(push�down�distance�every�0,15�mm)
Hardness�(HV01)
500
400
300
200
100
0
1 105 2015 3025 4035
after�hot�forming
before�hot�forming
For�crash-optimized�lightweight�design
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Hotform�Blanks�(3)
Example�Side�Member
• Combination�of�different�grades
• Application�of�one�step�process�confirmed
• Reduction�of�metal�forming�
transactions�by�using�hot�forming
For�cost-optimized�lightweight�design
manganese-boron-steel
MBW® 1500�+�AS
1,20�mm
micro�alloyed�steel
MHZ�340�+�AS
1,20�mm
FR
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Hotform�Blanks�(4)
Potential�Applications�Pulsatingsolidstatelaserinuse
• Removingofthecoatingoneachside
oftheweldgapisessential
• Newdevelopmentoftheproduction
systemcorrespondingtotheconti-
system
• Newdevelopmentofthequalitycontrol
For�lightweight�design�and�crash�standards
Bumper
Side�impact�beam
Roof�frame
B-Pillar
C-Pillar
A-Pillar
Dash�panel
Tunnel
Sill�plate
Side�member
Bumper
Frontal�crash Side�impact
TKAS (Changchun) Tailored Blanks Ltd.
Patchwork-Technologies�(1)
– Process�and�Serial�Parts
Patchwork�process
Insertion�of�local�reinforcement�by�means�of:
• spot�welding�(series)
• laser�welding�(prototypes)
• bonding�(still�under�way)
Patch
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Patchwork�Blanks�(2)
Determination�of�possible�production�concepts
Door�inner�panel�
with�local�patches�
for�lock�reinforcement
Engine�hood�inner
with�local�patches
Engine�hood�inner�
with�local�patches
Engineered�Blank�
with�patches
Tailored�Blank�
with�patchesPatchwork�Blank�
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Patchwork�Blanks�(3)
8�quilting�seams
Ground�blank
Patch
Blank�– upper�side Blank�– lower�side
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Patchwork�Blanks�(4)
Prototypes
Big�area�remote�with�long�focal�width/CO2-laser
TKS�Window�Lid
A-pillar�/�MBW® 1500�+�AS
Reinforcement�b-pillar�left
Reinforcement�b-pillar�right
Suspension�dome�/�MBW® 1500�+�AS
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Tailored�Blanks
Part�optimization�in�series�parts�(1)
Tailored�Blanks�potential�will�not�be�tapped�today.The�combination�of�different�grades�offer�significant�cost�and�lightweight�potentials.
0.500
Survey�– Thickness�relation�to�mechanical�characteristics
1.000 1.500 2.000 2.500 3.000 3.5000.000
0.500
1.000
1.500
2.000
2.500
Yield�strength�ratio
Thickness�ratio
Conventional�Tailored�
Blank
Lightweight�optimized�
Tailored�Blank
MHZ�260
2�mm
MHZ�260
1�mm
DX56
1,5�mm
MHZ�260
1�mm
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Tailored�Blanks
Part�optimization�in�series�parts�(2)
Costs�and�weight�reduction�through�optimization�proposals
Example
0.800 1.000 1.200 1.4000.000
0.500
1.000
1.500
2.000
2.500
Thickness�ratio
Yield�strength�ratio
Price�reduction
Weight�reduction
Actual�geometry /�optimization
H300LAD�+Z100MB
1.65�mm
H220PD�+Z100MB
2.00�mm
H220PD�+Z100MB
2.00�mm
H220PD�+Z100MB
1.00�mm
H220PD�+Z100MB
1.00�mm
H300LAD�+Z100MB
1.65�mm
Advantages�of�geometry�and�grade�optimization
• Higher�material�utilization�possible
• Reduced�Tailored�Blank�weight�about�16.9�%��
• Support�to�achieve�CO2�targets
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Tailored�Blanks
Part�optimization�in�series�parts�(3)
0.800
Example�side�panel
1.000 1.200 1.400 1.600 1.800 2.0001.800
1.900
2.000
2.100
2.150
2.200
Yield�strength�ratio
Thickness�ratio
2.050
1.950
1.850
Costs�and�weight�reduction�through�optimization�proposals�
MHZ�340
1.2�mm
HX�180
0.65�mm
Advantages�of�geometry�and�grade�optimization
Higher�material�utilization�possible;�support�to�achieve�CO2 targets
Actual�geometry
Optimization
Price�reduction
Weight�reduction
TKAS (Changchun) Tailored Blanks Ltd.
Welded�from�two�to�five�slit�strips�of�different�grade,�thickness�and/or�finish
Production�process:
• Downcoiling and�leveling�the�strips
• Weld�edges�prepared�for�high�welding�speeds
• 3�strips�laser�welded�together�in�one�production�step
• 100%�weld�checking�by�quality�assurance�systems
• Defects�marked
• Tailored�Strips�upcoiled or�cut�to�length�at�exit�from�line
Tailored�Strips are�Tailored�Blanks�direct�from�the�coil
The�new�product:�ThyssenKrupp�Tailored�Strips�(1)
TKAS (Changchun) Tailored Blanks Ltd.
ThyssenKrupp�Tailored�Strips�(2)�– production�line
DowncoilerLeveler
Edge�preparation
Pinch�roll�units
Pinch�roll�units
Strip�guide
Welding�table�1
Welding�table�2
Pinch�roll�unit
Up-
coiler
TKAS (Changchun) Tailored Blanks Ltd.
Material�combinations�in�Tailored�Strips�(3)
DC04 MHZ�340 DX56 DP-K®34/60 DP-K®45/78 DP-K®60/98 1.4301* 1.4509** 22MnB5 FB-W® 450
DC04
MHZ�340
DX56
DP-K®34/60
DP-K®45/78
DP-K®60/98
1.4301*
1.4509**
22MnB5
FB-W® 450
Carbon�steel Heat-treat- steel
Dual-phase�steel Fine�grain�steel
Stainless
successfully�
produced
*�Austenitic�stainless�steel
**�ferritic stainless�steel
development
ongoing
not�yet�
produced
TKAS (Changchun) Tailored Blanks Ltd.
1. Front�and�rear�door�left/right�
2. Anti-intrusion�reinforcement
3. Rear�roof�cross�member�and�reinforcement�
Tailgate�fastener�left/right
4. Front�seat�cross�member�left/right
5. Seat�cross�member�left/right
6. Cross�member�before�floor�panel
7. A-pillar�reinforcement�and�hinge�
reinforcement
8. Front�roof�cross�member�and�reinforcement�
left/right
Potential�uses�for�Tailored�Strips�(4)�in�auto�construction
8 3
1
2
7
4
5
6
TKAS (Changchun) Tailored Blanks Ltd.
Roof�frame�of�Tailored�Strips�(5)�using�progressive/compound�dies
Width:�238.1�mm
Thickness:�1.0�mm
Width:�476�mm
Thickness:�0.7�mm
Width:�238.1�mm
Thickness:�1.0�mm
Material�flow
Total�width:�952.2�mm
TKAS (Changchun) Tailored Blanks Ltd.
Seat�cross�member�made�from�Tailored�Strips�(6)
CP-W® 800
2.0�mm
CP-W® 1000
1.5�mm
CP-W® 800
2.0�mm
Stamped�seat�cross�
member
266
140 270 140
TKAS (Changchun) Tailored Blanks Ltd.
1. t�=�1.5�mm
B�=�225�mm
2. t�=�1.0�mm
B�=�350�mm
3. t�=�1.5�mm
B�=�225�mm
Progressive/compound�die:�
35�strokes/min.
Reinforcement�made�from�Tailored�Strips�(7)��using�
progressive/compound�dies,�material:�MHZ�340
1 2 3
TKAS (Changchun) Tailored Blanks Ltd.
1. t�=�1.2�mm
B�=�112�mm
2. t�=�0.7�mm
B�=�366�mm
3. t�=�1.2�mm
B�=�97�mm
Tailored�strips�(8)Exhaust�system�of�stainless�steel�Material:�stainless�steel�1.4301
Upper�and�lower�shell�separate� Upper�and�lower�shell�joined�
1
2
3
TKAS (Changchun) Tailored Blanks Ltd.
Actual�Tailored�Blank�Highlights�(1)
Inner�Panel�Bodyside Reinforcement�L�or�R
“O” part,�Xiao�Ben�Teng,�FAW-CC
Welding of
TRIP600/TRIP800
TKAS (Changchun) Tailored Blanks Ltd.
Actual�Tailored�Blank�Highlights�(2)
Inner�Panel�Front�Bodyside L�or�R
“C” part,�Xiao�Ben�Teng,�FAW-CC
TKAS (Changchun) Tailored Blanks Ltd.
Quality assurance
Online:
�Geometric Falldorf System
�Hole Detector,
�Plasma Sensor
Spot check:
�Impact Test (cup test)
��Stepnaht�(discontinuous welding line)
�Sample comparison
�Statistic visual inspection
�Root width
TKAS (Changchun) Tailored Blanks Ltd.
References (1)
Xiali�Veizhi
FCC�Besturn
FAW�VW�SagitarFAW�VW�Audi�A6L FAW�VW�Magotan
FCC�Xiao�Ben�
Teng
Daimler�
C-Class
Daimler�
E-Class
FCC�Rui yi
ThyssenKrupp (Wuhan) Tailored Blanks Ltd.
References (2)
Focus
Mazda�3
New�Mondeo
S-max
Volvo�S80
La�Crosse
GL8
New�Regal
Cruz
Cadillac
Royaum
Peugeot�207
C2
Peugeot�307
c-Triomphe
TKAS (Changchun) Tailored Blanks Ltd.
Thank�you�very�much�for�your�attention
感谢您的关注感谢您的关注感谢您的关注感谢您的关注