Dr.-Ing. Hosen SULAIMAN, Klaus UNRUH 16 June Steel in Automotive Industry The View from the Supply Chain

Transcription

1 Dr.-Ing. Hosen SULAIMAN, Klaus UNRUH 16 June 2015 Steel in Automotive Industry The View from the Supply Chain

2 Agenda Introduction Current situation on steel usage and delivery Material approval and future needs Conclusion and Outlook Steel in automotive industry - METEC & 2nd ESTAD June

3 Faurecia Group 34 countries patents filed in sites billion of total sales* 6,000 engineers and technicians 99,500 employees 30 R&D centers Automotive Seating Interior Systems Emissions Control Technologies Automotive Exteriors Steel in automotive industry - METEC & 2nd ESTAD June

4 Trends and challenges in the automotive industry Expanded regulatory requirements Globalization Mega Platform, Standards Safety Shift customer demand Demand on lighter car Steel in automotive industry - METEC & 2nd ESTAD June

5 Vehicle weight increased until end of 2000 s Weight evolution over 7 VW Golf Generations Vehicle unladen weight (kg) 1300 Other cars are following the same trend Golf VI VW Golf Renault Clio 1100 Golf IV Golf V Golf VII Peugeot (205 to 208) Ford Fiesta 900 Golf III OEM forecast 700 Golf I Golf II Time (year) Source: Auto evolution Steel in automotive industry - METEC & 2nd ESTAD June

6 Car weight split and the total target Car weight 1300 Kg Emission treatment systems Performance systems for better acceleration, handling & braking Occupant safety such as airbags, pretensioner Infotainment & other electrical systems Comfort systems air condition, seats 800 Kg Improved Noise, Vibration, Harness & handling 750 Kg Increase in vehicle dimension longer, wider, taller cars Target Delta weight target: 500 kg (~40%) Reference C segment car (Golf and equivalent) Steel in automotive industry - METEC & 2nd ESTAD June

7 Usage growth of AHSS in the automotive industry Source: Ducker Worldwide Steel in automotive industry - METEC & 2nd ESTAD June

8 Material family for cold forming process higher strength level higher process effort smaller process window Higher Strength Steels require higher process expertise Steel in automotive industry - METEC & 2nd ESTAD June

9 Global supply chain, considering local suppliers Steel in automotive industry - METEC & 2nd ESTAD June

10 Complex Material Landscape with different standards ASTM HSS, AHSS Focus on Yield Strength for HSS Tensile test length: 50 mm (ASTM) EN HSS, AHSS Focus on Yield Strength for HSS but on Tensile Strength for AHSS Tensile test length: 80 mm (DIN) JIS HSS, AHSS Focus on Tensile Strength Tensile test length: 50 mm (JIS) GOST ASTM SAE EN IS GB JIS JFS NBR IRAM-IAS OEM spec. VDA ? Steel in automotive industry - METEC & 2nd ESTAD June

11 Material Approval - Testing Mechanical properties - tensile testing - anisotropy - hardness - folding Frames Material structure - grain size - phase fraction analysis - microstructure - alignment Mechanisms Chemical composition - bulk element analysis - carbon equivalent Steel in automotive industry - METEC & 2nd ESTAD June

12 Tensile strength, MPa Scattering analysis strength - S355MC S355MC (E-A) S355MC (E-T) S355MC (I-E) S355MC (R-N) S355MC (R-S) S355MC (C-W) Yield strength, MPa Steel in automotive industry - METEC & 2nd ESTAD June

13 Tensile strength, MPa Scattering analysis strength DP1000/ CP CR550Y980T-DP CR700Y980T-DP CR780Y980T-CP CR700Y980T-DP (E-S) CR780Y980T-CP (E-A) CR700Y980T-DP (E-A) CR780Y980T-CP (K-P) CR550Y980T-DP (C-B) CR700Y980T-DP (J-K) CR780Y980T-CP (E-V) Yield strength, MPa Steel in automotive industry - METEC & 2nd ESTAD June

14 Material Approval - Statistical analysis Evaluation of data Scatter analysis Flow curves for FEA Martensite Steel in automotive industry - METEC & 2nd ESTAD June

15 Important material data for product and process development Work hardening Edge cracks Bulge Test Flow curve Yield Loci Failure criteria FLC HHE Compres sion Stretchability Bendability Anisotropy Steel in automotive industry - METEC & 2nd ESTAD June

16 Is the data sufficient for application? Unanticipated formability problems: No proven method to predict split in the extruded holes Cut edge stretching limit Split in compression area (luggage corner) is not predicted by FLC Bending radii, cracking limit. Steel in automotive industry - METEC & 2nd ESTAD June

17 Future demand AHSS with higher formability Common, extended testing procedures: Dome stretching, FLC total elongation Hole expansion local elongation Edge stretching local elongation Bending local elongation Compression Required specific steel grade will depend on product and process design Steel in automotive industry - METEC & 2nd ESTAD June

18 Conclusion and Outlook Increase usage of AHSS Automotive challenges Safety Environment Globalization Lightweight Thickness reduction Higher strength material Formability reduction Higher scattering Local standard Future priorities Close collaboration between steel makers and users Standard method for characterization Specific process related testing Harmonizing the testing procedure for better comparison Higher development complexity Small process window No standardized testing method to evaluate process ability Different material standard / behavior Geometry complexity Steel in automotive industry - METEC & 2nd ESTAD June

19 Thank you for your attention!