Advanced Steel Products for DaimlerChrysler North America

Transcription

1 Advanced Steel Products for DaimlerChrysler North America JP Singh DaimlerChrysler Corporation March 9 th, 2005

2 Acknowledgements Paul Belanger DR Team Tom Seel, Dennis Runyon LX Team Shan Haq, Vinod Makam, Subhash Shetty CAE Group Ajit Desai, Vinay Shah, Jim Prencipe - Materials Engineering 2

3 Outline Material Trends Requirements Safety NVH Corrosion Structural Material Trends Pacifica 300C/Magnum/Charger Jeep Grand Cherokee C-Segment Intrusion Control Materials/Processes General Applications Side Crush Roof Crush Conclusions 3

4 Outline Material Trends Requirements Safety NVH Corrosion Structural Material Trends Pacifica 300C/Magnum/Charger Jeep Grand Cherokee C-Segment Intrusion Control Materials/Processes General Applications Side Crush Roof Crush Conclusions 4

5 Passenger Safety - Objectives Crash Energy Management FMVSS MPH - Rigid Goal: barrier High peak deceleration in the beginning and low peak in the end Longer Insurance time duration Institute of of crash Highway pulse Safety 40MPH 40% Offset Deformable Barrier Non-Regulatory (In US) 5

6 Passenger Safety - Objectives Intrusion Control FMVSS MPH IIHS Side - Under review to account for higher impact height of light Goal: trucks and SUV s. Minimal A, B, intrusion and C Pillars become much more Low occupant important numbers FMVSS 216 Quasi-Static loading of 1.5x vehicle weight at A-Pillar area (up to 5000lbs). 6

7 Other BIW Requirements NVH (Noise, Vibration, Harshness) & Vehicle Handling Corrosion =Stiffness/Torsional Rigidity & Fatigue 7

8 100% 90% 80% 70% 60% Coated versus Uncoated Steel Trend 50% 40% 30% Uncoated Zinc Coated 20% 10% 0% Model Year 8

9 Outline Material Trends Requirements Safety NVH Corrosion Structural Material Trends Pacifica 300C/Magnum/Charger Jeep Grand Cherokee C-Segment Intrusion Control Materials/Processes General Applications Side Crush Roof Crush Conclusions 9

10 Structural Material Trends DCC Galvanneal Dual Phase 590 MPa Steel Reinforcement Side Front Rail to Dash 1.4mm 10

11 Structural Material Trends DCC Chrysler Dodge 300 Charger C 2005 Dodge Magnum 11

12 Light Weight (Materials/ Construction) HSS Steel Structural Material Trends DCC 12

13 Light Weight : Materials / Construction Near Double Parts with High Strength Steel (HSS) 98 20% HSS 05 37% HSS Dual Phase Steel for Front Rails 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% % # of parts '98 300M '05 300C >= 550 Mpa >= 340 Mpa >= 280 Mpa 13

14 Light Weight : Materials / Construction C HSS Part >= 280 MPa Yield 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% % # of parts '98 300M '05 300C >= 550 Mpa >= 340 Mpa >= 280 Mpa 14

15 Light Weight : Materials / Construction C HSS Parts >= 340 MPa Yield 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% % # of parts '98 300M '05 300C >= 550 Mpa >= 340 Mpa >= 280 Mpa 15

16 Light Weight : Materials / Construction Galvanneal coated Dual Phase 590 MPa Steel 1.52 mm gauge 16

17 Structural Material Trends DCC 2005 Jeep Grand Cherokee Grand Cherokee 17

18 Rail Assemblies Exploded View Rail Assemblies FRONT OF VEHICLE FRONT OF VEHICLE 18

19 Rail Front Outer FRONT OF VEHICLE Rail Front Inner 1.85 mm FRONT OF VEHICLE Hot Dip GA DP mm Hot Dip GA DP590 19

20 Reinforcement Front Rail U-Channel FRONT OF VEHICLE Rail Front Rear 1.80 mm Hot Dip GA DP590 FRONT OF VEHICLE 2.21 mm Hot Dip GA DP590 20

21 Reinforcement Shock Tower 1.40 mm Hot Dip GI DP590 Rear Rails FRONT OF VEHICLE 2.01 mm Hot Dip GA DP590 21

22 A-Pillar Front Upper 1.70 mm Hot Dip GA DP590 A-Pillar Rear Upper Extension 1.70 mm Hot Dip GA DP590 22

23 Structural Material Trends DCC C Segment (BIW) 1% 4% Mild 13% 3% 11% 1% 4% 1% * weight percent 62% 830/ 860 RA BH/ IF-Rephos 280/ 340 SS 340/ 620 HSLA 280/ 440 W 340/ 590 DP Martensitic Hot Stamped 23

24 Outline Material Trends Requirements Safety NVH Corrosion Structural Material Trends Pacifica 300C/Magnum/Charger Jeep Grand Cherokee C-Segment Intrusion Control Materials/Processes General Applications Side Crush Roof Crush Conclusions 24

25 Direct hot stamping Intrusion Control Hot Stamping Coil Platine Presse Coil Blank Furnace Robot Indirect hot stamping Press Cooling system Courtesy of Benteler Automotive Press (preforming / trimming) Coil Blank Furnace Robot Press Cooling system 25

26 Roll Forming Intrusion Control Selective Heat Treatment fixture length for hardening ring inductor fixture 26

27 Intrusion Control General Applications Side Intrusion Frontal/Rear Crash 27

28 Intrusion Control Hot Stamping Hot Stamping (direct) Geometry Hot Stamping with preforming (indirect) 28

29 Hot Stamped Door Beams Dodge Dakota Dodge Durango Dodge Ram Jeep Grand Cherokee 29

30 Jeep Grand Cherokee Front Door Impact Beam 2.1 mm Hot Stamped 1.7 mm Hot Stamped LEFT HAND SIDE VIEW Rear Door Impact Beam 30

31 Hot Stamped Parts - 13 lbs 1.0 mm Tailor Rolled Blank Center Pillar Inner 1.9 mm 1.6 mm 1.8 mm 1.0 mm lbs Reinforcement Windshield Opening Inner lb Roof Rail Inner 31

32 Front Header Recovery annealed 830/900 CR RA 830/900 Roof Crush Front Header Dual Phase 340/590 GA DP 340/590 Dakota Durango 32

33 Outline Material Trends Requirements Safety NVH Corrosion Structural Material Trends Pacifica 300C/Magnum/Charger Jeep Grand Cherokee C-Segment Anti-Intrusion Materials/Processes General Applications Side Crush Roof Crush Conclusions 33

34 Sheet Steel Usage Trend * weight percent UHSS 6% AHSS 40-45% UHSS 10% Mild & Medium 35-40% HSS 10% AHSS 10% UHSS 2% AHSS 24% HSS 18% Mild & Medium 52% Future (10 yrs) HSS 24% Mild & Medium 64% Intermediate (3 to 5 yrs) Current - Imminent (up to 2 yrs) 34

35 Conclusions (contd.) Chrysler Group s market of high volume vehicles at competitive prices, is driving extensive use of steel. Increasingly stringent regulations and aggressive corporate goals for safety and fuel economy are driving the increased usage of high, advanced, and ultra high strength steels. Although multi-material designs will be utilized, steel will remain the dominant body material of choice for the foreseeable future. 35