Advanced High Strength Steel Technology in the Ford 500 and Freestyle Ford Motor Company March 9, 2005 w w w. a u t o s t e e l. o r g
Agenda Overview of Products Presentation Scope / Purpose Assumptions / Challenges Materials and Application Formability and Welding Lessons Learned Conclusions 2
Ford 500 3
Ford 500 Redefining the North American sedan is a tall order We took a look at the attributes that make crossovers popular like highpackage command seating and sought to deliver some of those qualities in a sedan. While the industry tries to create new carbased crossovers, the Ford Five Hundred stands alone as the first crossover-based car. Phil Martens Group Vice President Product Creation Ford Motor Company 4
Ford Freestyle 5
Ford Freestyle Freestyle is the crossover done right. We didn t try to adapt an existing minivan or sport utility platform. Freestyle is built from the ground up as a crossover with class-leading spaciousness, seven-passenger comfort, versatility and all-wheel-drive capability. And through it all, Freestyle will deliver with the value that defines it as a Ford... Phil Martens Group Vice President Product Creation Ford Motor Company 6
Selling Features Ford 500 Highest Seating position of any sedan. Confident and commanding driving experience Unparalleled convenience and storage Effortless entry and exit Exceptional interior roominess Safety and confidence of AWD Ford Freestyle Carry 7 adults in total comfort Totally flat load floor with 2 nd and 3 rd row seats folded down Unparalleled convenience and storage Most flexible/versatile interior Effortless entry and exit AWD for safe and confident driving. 7
Agenda Overview of Products Presentation Scope / Purpose Assumptions / Challenges Materials and Application Formability and Welding Lessons Learned Conclusions 8
Presentation Scope / Purpose Body in White on the 2005 Ford 500, Freestyle, and Mercury Montego No Breakthrough Technology presented, but an Implementation History, Success Story, and Lessons Learned on one Vehicle Platform Information Sharing 9
Agenda Overview of Products Presentation Scope / Purpose Assumptions / Challenges Materials and Application Formability and Welding Lessons Learned Conclusions 10
Building Blocks Architecture and Energy Management Strategy evolved from Volvo P2X Platform. Extensive global sharing of information and technology. Volvo and Ford Europe implemented DP600 in 1990 s. Volvo had been utilizing DC Welding vs. Ford NA AC Welding. 11
Major Implementation Challenges Freestyle and 500 share Platform Sedan and Cross-over. Common Front Structure, Common Front Floor, Common Bill of Process Ford NA did not have any approved NA Suppliers for DP600. Required concurrent implementation and Certification processes MFDC Welding was viewed as a key enabler for implementing DP600, but was not part of Ford NA Toolset Production Draws at CP Prototype Build Rising Steel Prices, Fuel Economy Targets, and a goal of Outstanding Safety Performance 12
Agenda Overview of Products Presentation Scope / Purpose Assumptions / Challenges Materials and Application Formability and Welding Lessons Learned Conclusions 13
Stress/Strain curves 800 Engineering Stress (MPa) 600 400 200 Mild Steel HSLA (50F) DP600 TRIP600 0 0 10 20 30 40 50 Engineering Strain (%) 14
Dual Phase vs. HSLA Relative Performance DP600 HSLA Formability ++ + Weldability ++ +++ Fatigue +++ +++ Energy Absorption +++ ++ Bake Hardening +++ + Work Hardening +++ + 15
Dual Phase vs. HSLA Component Material Strength DP 350/600 HSLA 350/450 Sheet YS Work-Hardening Bake-Hardening Strength 0 100 200 300 400 500 600 Yield Strength 16
Material Usage by Mass on Ford 500 59% 14% 12% 0% 15% HSLA250 HSLA350 HSLA550 DP600 Mild Steel 17
Ford 500 Green: HSLA 250 Blue: HSLA 350 Yellow: HSLA 550 Red: DP 600 Purple: Inner: Top DP600 / Bottom HSLA 250 Outer: Top DP600 / Bottom Mild Steel 18
Ford 500 Green: HSLA 250 Blue: HSLA 350 Yellow: HSLA 550 Red: DP 600 Purple: Inner: Top DP600 / Bottom HSLA 250 Outer: Top DP600 / Bottom Mild Steel 19
500 Safety Success Frontal 5 Star for Driver and Passenger!!! 20
Ford 500 Load Path - Frontal TWB HSLA Front Rail DP600 Dash xmbrs DP600 Y-Brace DP600 Side Member HSLA Tunnel 21
Ford 500 Load Path -Frontal HSLA Shotguns/Rails HSLA Cowl Sd Inr Pnl Upper / Lower Load Path 22
500 Safety Success Side Impact 5 Star for Front Seat and Rear Seat without Side Airbags!!!!! 23
Ford 500 Load Path Side Impact TWB DP600 B-Plr Inr/Otr HSLA 550 Ctr Roof Bow HSLA Crossmbrs DP600 Side Mbr 24
Ford Freestyle Green: HSLA 250 Blue: HSLA 350 Yellow: HSLA 550 Red: DP 600 Purple: Inner: Top DP600 / Bottom HSLA 250 Outer: Top DP600 / Bottom Mild Steel 25
Ford Freestyle Green: HSLA 250 Blue: HSLA 350 Yellow: HSLA 550 Red: DP 600 Purple: Inner: Top DP600 / Bottom HSLA 250 Outer: Top DP600 / Bottom Mild Steel 26
Ford Freestyle Bottom View Unique Reinfs for 2 nd Row Seats vs. 500 27
Futured Safety Performance Both 500 and Freestyle are already: Designed to meet new FMVSS 208 front impact Designed to meet upcoming FMVSS 301 rear impact 28
Body Stiffness Vs. Competition 16000 Freestyle 500 N/mm 12000 8000 M ercury Sable BMW X5 Toyota Camry M azda 6 Mazda 6 Toyota Camry To yo ta Highlander Lexus RX300 Mazda 6 Audi A8 Toyota Avalon Honda Accord Lincoln LS Ford TAURUS BM W 330i Coupe Honda Civic Toyota Celica Ford D258 CP1 CD338 ADV Ford D219 CP1 BM W 328i 4000 0 1992 1994 1996 1998 2000 2002 2004 2006 2008 MY 29
Agenda Overview of Products Presentation Scope / Purpose Assumptions / Challenges Materials and Application Formability and Welding Lessons Learned Conclusions 30
Formability Lessons Learned DP steels have an excellent work hardening coefficient, and hence, are difficult to re-draw Final part geometry should be obtained in initial draw DP steels require higher blank holder forces than HSLA steels. (20-30% higher than HSLA 350.) Drives higher die construction costs, revised / upgraded die materials, and revised press tonnage strategy Incremental die tryout time required to manage spring-back corrections 31
Welding Considerations Increasing stackup thickness ratios due to the use of thinner gage components. Joint spring back for short hold times during weld cycle. Weld quality verification acceptance criteria Weld button formation vs. interfacial separation. Ergonomics in teardowns. Welding specifications and standards. 32
Welding Lessons Learned No issue with interfacial separation, even with the use of an air hammer and chisel. Difficulty with thin-thick-thick stackups (more than typical). Longer weld time has been necessary. 33
Welding Requirements Dual-headed, frequent tip dressing. Adaptive weld controls may be required as we go beyond DP600. Technology is currently being proven out. Additional weld teardowns AHSS in a subassembly will increase the number of non-pryable welds. 34
Agenda Overview of Products Presentation Scope / Purpose Assumptions / Challenges Materials and Application Formability and Welding Lessons Learned Conclusions 35
Conclusions / Success Enablers (Slide 1 of 2) Use of AHSS enabled weight efficiency and world class performance Use of global architecture sharing Integration of manufacturing/product development teams Intensive use of CAE tools for safety, NVH, durability - and stamping FEA tools 36
Conclusions / Success Enablers (Slide 2 of 2) TWB usage in front rails and B-Pillar construction MFDC welding implementation Early and intensive supplier involvement Intensive dimensional control strategy including production draws and production assembly tooling at CP build 37
Acknowledgements Paul Schurter / Sean Martin - Dofasco Todd Mueller Ford Body Structures Ted Coon Ford VOGO Welding Dr. Don Jordan Ford Materials 38
Thank you for your Attention. Please feel free to contact me at: mlee7@ford.com 39