Volvo Fredin

7/29/2019 Volvo Fredin

1/12

Uddeholm Automotive Seminar 2005-02-09

Advanced

BodyEngineering

Future materials for body structure applicationsFuture materials for body structure applications


Kaj Fredin, Advanced Body Engineering Volvo Car Corporation

Volvo Car Advanced Body EngineeringVolvo Car Advanced Body Engineering

YesterdayYesterday--TodayToday--TomorrowTomorrow

OptimalOptimal

material MIXmaterial MIX

OptimalOptimal

material MIXmaterial MIX

Advanced

BodyEngineering


2/12


Advanced

BodyEngineering


Process investments Cost Technology step Commonality

Comfort Safety Reliability Cost EnvironmentFuel

consumptionDesign

Customer

satisfaction

Stiffness

Strength

Panel fit Weight Flexibility

Surface

finish

Material

Structure

Joint

Complete vehicle Properties

Car Body Properties

Basic Body Technology Parameters

Durability

Colour

Corrosion

protection

Drivers & constraintsDrivers & constraints


3/12


Advanced

BodyEngineering


FactsFacts-- Trends & Wanted PositionTrends & Wanted Position

! !

168gCo2/km ! 145gCo2/km !

2008 2012Mainly carbon steel, moderate level ofcontinuous joints in conventional uni-body

produced in current process

Time850 S80 S60 XC90 S40+ S80+ XC90+

?

Necessary

Technology

Shift

2000 2006 2009

Wanted Position

2009

Total Passive

Safety Performance

Projected body weight

Cost

The Steel Era

! !


2008 2012

! !


2008 2012Mainly carbon steel, moderate level ofcontinuous joints in conventional uni-body


Mainly carbon steel, moderate level ofcontinuous joints in conventional uni-body


Time850 S80 S60 XC90 S40+ S80+ XC90+

?

Necessary

Technology

Shift

Necessary

Technology

Shift

2000 2006 2009

Wanted Position

2009

Total Passive

Safety Performance


Cost

Total Passive

Safety Performance


Cost

The Steel Era


4/12


Advanced

BodyEngineering


The average weight development corresponds to an annual increase of fuel consumption of 0,052l/100km

(corresponding to approximately 1,2 gCO2/km). The weight increase results from increased requirements

in NVH, safety, convenience, driving & up-sizing

Body & trim weight

contribution is currently50-53% of the total car

weight. The average

weight of the car has

increased at a rate of 10kg

per annum, platform to

platform

Weight developmentWeight development


5/12


Advanced

BodyEngineering


P1X54% HSS

23% >HSS

XC9057% HSS

21% >HSSS80

36% HSS

2% >HSS

85036% HSS

0% >HSS

74015% HSS

0% >HSS

2400% HSS

0% >HSS

% HSS(Rm>340MPa)

% EHSS>(Rm>600MPa)

S8059% HSS

25%

>HSS

0

10

20

30

40

50

0

10

20

30

40

50

Approximate values

Steel sheet development within Volvo CarSteel sheet development within Volvo Car


6/12


Advanced

BodyEngineering


Tensile Strength, Rm (MPa)

Yield Strength, Re (MPa)

max170-280 min220 min280 min400

max270-390 min340 min600 min800MS HSS EHSS UHSS

Rephos

HSLA

DP

Rephos

HSLA

DP

HSS: HSLA & RephosStandard qualities for high strength

steel sheets. Rephos higher formability

compared to HSLA.

HSS/EHSS: DP-steelsUsed for reinforcements and safety

components for high load capacity and

balanced weight impact, e.g. B-pillar

reinf., roof bow, sill reinf.

UHSS: Boron-steelsSimilar applications as DP-steels andfor extreme load cases, e.g. bumper

beams, B.pillar reinf., roof bows.

Boron steel

Boron steel

HighHigh StrengthStrength SteelSteel Sheets, EHSSSheets, EHSS within Volvo Car Stdwithin Volvo Car Std

(Rpmin >220 Mpa, Rmmin >340 Mpa)


7/12


Advanced

BodyEngineering


Material GradeDistribution (%-weight)

HSS

EHSS UHSS

HSS

EHSS UHSS

XC90XC90XC90

46%

31%

20%3%

1%

47%

32%

13%7%

S40S40S40S40 new Volvo patented front end, same concept

as XC90. Frame of beams working in

compression and tension instead of bending.

Rephos

DP600 Boron

Volvo Car state of the art steel body structuresVolvo Car state of the art steel body structures

Al

MS (Rp


8/12


Advanced

BodyEngineering


Not taking strain hardening into account = over dimensioning !Not taking strain hardening into account = over dimensioning !

virgin

2% strain5% strain

320

500

650

Plastic strain

Trues

tress(MPa)

DP600, Stress-Strain for different pre-strain levels

virgin

2% strain5% strain

320

500

650

Plastic strain

Trues

tress(MPa)

virgin

2% strain5% strain

320

500

650

Plastic strain

Trues

tress(MPa)


virgin

2% strain5% strain

320

500

650

Plastic strain

Trues

tress(MPa)


virgin

2% strain5% strain

320

500

650

Plastic strain

Trues

tress(MPa)

virgin

2% strain5% strain

320

500

650

Plastic strain

Trues

tress(MPa)


The ExtraThe Extra HighHigh StrengthStrength SteelSteel challengechallengeLesson learned, DP600 front side member application S40


9/12


Advanced

BodyEngineering


The suppliers different material concepts,

process ability & scatter are concerns

Continue reducing weight with Advanced High Strength SteelsContinue reducing weight with Advanced High Strength Steels

Reaching an additional 5% cost efficient weight reduction

DP600

Boron

steel

MS-W1200:

DP600

Boron

steel

MSW 1200

DP600

Boron

steel

MS-W1200:

DP600

Boron

steel

MSW 1200

MSW 1200: Martensitic hot rolled steel

CP 800: Complex phase hot rolled steel

Trip 700: Transformation Induced Plasticity cold rolled steel

DP: Dual phase cold rolled steels

Today

Tomorrow

>86,5Rmmin >800UHSS>1814Rmmin >600EHSS

Rmmin >380-420

Rmmin >340HSS

(%)(%)(Mpa)


10/12


Advanced

BodyEngineering


And then ?And then ?Austenitic stainless steels

Combining high strength with excellent formability !!

Driver: Enabling weight reduction 1 step

further than high strength steel. Lower mix-

material risk compared to aluminium

Target: 40% weight reduction at lower

cost/save kg than Aluminium.

Driver: Enabling weight reduction 1 step

further than high strength steel. Lower mix-

material risk compared to aluminium

Target: 40% weight reduction at lower

cost/save kg than Aluminium.

B pillar section;

Sill

B pillar

Roof bow

Cant rail

B pillar section;

Sill

B pillar

Roof bow

Cant rail

Front section;

Bumper beam Crash box

Side member lower

Radiator beam

Spring-

tower

Front section;Front section;


Side member lower

Radiator beam

Spring-

tower


Side member lower

Radiator beam

Spring-

tower


11/12


Advanced

BodyEngineering


Other light weight body structure materialsOther light weight body structure materialsInteresting or not ?

Fibre reinforced polymersi.e. Ip-structure, spare wheel well, parcel shelf

Sandwich materialsi.e. floor panels, roof, hood

Die cast magnesiumi.e. Ip-structure, SIPS-box

Aluminium (extrusion, castings & sheets)for various structural applications

Weight

P.Safety

Cost

Weight

P.Safety

Cost

Weight

P.Safety

Cost

Weight

P.Safety

Cost

Weight

P.Safety

Cost

Weight

P.Safety

Cost

Weight

P.Safety

Cost

Weight

P.Safety

Cost

PolymerMetal

JointsJoints

StructureStructure

MaterialsMaterials


12/12


Advanced

BodyEngineering


Magnesium

Multi phase steelsStainless steels

Continuousjoints

Structural

foams

Boron Steels

Aluminium

Fibre reinforced

polymers

Multi material usage

with high degree of

continuous joints in

upgraded structure

produced in a

modified process

Multi material usage

with high degree of

continuous joints in

upgraded structure

produced in amodified process

The future body structureThe future body structure

Improving passive safety & reducing weight at minimum cost

Properties

In balance !

Weight

Cost

Properties

In balance !

Weight

Cost

Volvo Fredin

Documents

Transcript of Volvo Fredin