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