LIGHT WEIGHT BODY IN WHITE DESIGN Jason Balzer Lightweight Body & Joining Technical Leader Ford Motor Company September 26 th, 2017
Agenda: Why Light Weight BIW Light Weight Design Mindset 2
Miles per Gallon Equivalent Fuel Efficiency Targets Light-Duty Vehicle Fuel Economy Standards, 1978-2025 54.4 mpge Fleetwide average in 2025 Model year Source: Green Technology, 2011. 3
Impact of Vehicle Mass on Fuel Economy The EPA says that for every 100 pounds taken out of the vehicle, the fuel economy is increased by 1-2 percent. Fuel Economy Sensitivity to Vehicle Mass for Advanced Vehicle Powertrains S. Pagerit, P. Sharer, A. Rousseau Rhett Allain - Wired In conventional ICE vehicles a 10% mass reduction; - Without powertrain re-sizing improves mpg between 1.9%-3.2%. - With powertrain re-sizing improves mpg between 2.6%-3.4%. Diesel engine Determination of Weight Elasticity of Fuel Economy for Conventional ICE Vehicles, Hybrid Vehicles and Fuel Cell Vehicles Forschungsgesellschaft Kraftfahrwesen mbh Aachen Body Department Lightweighting Impacts on Fuel Economy, Cost, and Component Losses; Aaron David Brooker, Jacob Ward, Lijuan Wang Gas Guzzler Weights Andrew Danowitz
Average Vehicle Mass / lbs Average Vehicle Mass 1980-2012 (NA) Since 1998, the average vehicle mass has increased by 17lbs /yr for cars 42lbs /yr for trucks Year Vehicles have increased in weight due to; Customer Features: Size, Options, etc. Safety Regulations & Features 5
BIW Mass Trend Mass of Ford Sedan BIWs are on a decreasing trend. From 2007 to 2017 Ford s average BIW reduction is 17%. Snap Shot of the Industry shows the average trending down 12.5% over the same time. More cost effective weight saves are required.
Light Weight Design Mindset 7
Optimized Design: Topology Optimization Mass savings starts at the early in the design phase by insuring that the optimal load paths are defined Establishing the ideal load paths allow energy transfer through the structure with the minimum amount of material and material strength Three applications of Topology: 1. Full Vehicle focus on defining the overall load path strategy based on vehicle level load conditions 2. System develop geometry to address specific loads within a given system 3. Component insure the geometry at the component level is optimized to the local events Full Vehicle System Level Component Level 8
Average Yield Strength Advanced High Strength Steel: DP600 & DP800 Mainstream Boron Advanced High Strength Steel: DP1000 Martensitic Steel High Strength Low Alloy Bake Hardenable Solution Strengthened Safety regulations and need for weight reduction have driven the need for higher strength steels Increase of up to 104% in the Average Yield Strength of Ford BIWs since 2008
Forming Processes and Geometry Utilize all available forming processes to: Enable the utilization of the highest strength materials available Improve the geometric properties of a given part End goal of achieving reduced cost and mass required to achieve a given level of performance Current focus is on Hot Stamping, Roll Forming, and Hydro-Forming Hydro-Forming Hot Stamping F-Series: Front End and Body Side Fusion: A-Pillar / Roof Rail & B-Pillar Mustang: A-Pillar / Roof Rail Roll Forming Edge: A-Pillar / Roof Rail & D-Pillar 10
Hydro-Forming Evolution STAMPED STEEL FIRST HYDROFORM STEEL FIRST ALUMINUM HYDROFORM 31 PARTS 18 PARTS 20 BENDS 31 % WEIGHT 12 PARTS 6 BENDS 59 WEIGHT % FRONT-END SUPER DUTY FRONT-END SUPER DUTY/EXPEDITION FRONT-END F-150 11
A-Pillar / Roof Rail: Closed Section Design Mild Gage: 1.2mm HSLA 350 Gage: 1.6mm DP1000 Gage: 1.5mm DP1000 Gage: 2.0mm HSLA 350 Gage: 1.8mm HSLA 350 Gage: 1.8mm DP1000 Hydro-formed Tube Gage: 2.0mm 2014 Mustang 2015 Mustang Vehicle Material Mass Savings Replacement of complex stampings with a tubular structure enables: The use of higher strength steel within a reduced package Increased vehicle performance Reduced package requirement Concept initiated on F-150 and proliferated across vehicle lines F-150 DP800 6.1 kg Fusion DP1000 4.2 kg Mustang DP1000 3.9 kg Continental DP1000 4.5 kg F-150 6000 Series Expedition 6000 Series 12
Boron - Hot Stamping Heating 880-930 C 3 10 min Transfer Stamping (600-800 C) + Hardening (>> 50 K/s ) 1 st Gen (production) Max strength stamping technology available. YS=> 1000 Mpa, TS=> 1300 Mpa. 2 nd Gen (pre-production) Inc. YS & TS. YS=>1400 Mpa, TS=> 1800 Mpa. No Springback, enabling complex parts. Technology is rapidly expanding. 2016 Civic = 14% Boron (from 1%) 2016 Volvo V90 = 29% Boron Civic 13 vs. 16 Volvo V90 16 Maximum High Strength Stamping material. Processing dependent. High Cost. 13
Tailored Material Thickness Variation of gauge allowed for the elimination of the B-Pillar Reinforcement Tailor Rolled Blank introduced to place gage where needed to meet the performance requirements and provide mass savings Mass savings of 1.2 kg achieved over the conventional Hot Stamping approach. Very costly weight savings technology 14
Stress [MPa] Aluminum: Post Form Heat Treatment Ford developed a novel Post Form Heat Treatment (PFHT) cycle for 6XXX sheet alloy (Industry-first) that results in a: 66% increase in Yield Strength 6% increase in Ultimate Strength PFHT is used to strengthen sheet parts for yield-limited applications 14 stamped parts undergo the PFHT operation PFHT Process STAMPING HEAT-TREAT OVEN BODY SHOP 350 300 250 200 150 PAINT 100 50 0 6HS2-T81 YS UTS 6HS2-T82 6HS2-PFHT 15
New Materials 3 RD Generation Advanced High Strength Steel Developments in steel related to 3 rd Generation Advanced High Strength Steel offer opportunities: Increased Yield Strength allows for gauge reduction of strength driven parts Yield Strength increased combined with improved ductility offer opportunities to optimize parts requiring energy absorption 16
Composites - Resent Usage within Ford Motor Company SMC Multiple Applications Hood (FN9 Continental, Mustang, Raptor, Windstar) Fenders (FN9 Continental, Raptor) Decklids (SN95 Mustang, MKS) Radiator Supports Carbon Fiber New Ford GT (Body Structures and Closures) Wheels (Ford Shelby GT) Battery Box Covers (PHEV, BEV) Driveshaft 2013 Shelby GT /// 17
Carbon Fiber Application Philosophy / Needs Philosophy Defining High Volume as about 100k units per year Considering performance line of vehicles (100 to 40k units per year) Weaves have too much operator handling to be efficient for Ford Motor Company volumes Applied in mixed material vehicles. Needs Lower cost materials & processing High volume joining methods and associated processes. Corrosion testing correlation with real life along with corrosion mitigation methods when used in conjunction with steel, aluminum and/or magnesium. In Plant repair methods. /// 18
Summary Stronger lighter vehicles are needed. Ford is reduced the BIW weight faster than the industry. Ford is open to any and all technology required to meet Regulatory and Customer requirements. We re interested in working with Suppliers that can deliver cost efficient weight reduction technologies. /// 19
THANK YOU 20
Electric Vehicle & Mass Analysis of Parameters Influencing Electric Vehicle Range; Martin Mruzek*, Igor Gajdáč, Ľuboš Kučera, Dalibor Barta A similar relationship between power required or range and vehicle mass exists for electric vehicles Lightweighting Impacts on Fuel Economy, Cost, and Component Losses; Aaron David Brooker, Jacob Ward, Lijuan Wang
B-Pillar: Closed Section Design Tube Rear Body Pillar 1.8 mm DP1000 Bracket Center Pillar Upper 1.2 mm DP800 Reinf Center Hinge Pillar 1.4 mm Boron Plr Bdy Lock Inr 0.75 mm HSLA 340 Reinf Ctr Bdy Plr - Upr 1.0 mm Boron Closed section concept was extended to the B-Pillar for the Fusion enabling: Elimination of large press hardened parts Use of AHSS Reduced intrusion during side impact 6 kg mass reduction Plr Bdy Lock Inr 1.2mm Boron Tube Front Body Pillar 1.4 mm DP1000 Hinge Reinforcement Outer 1.75 mm DP800 23
Sustainability Clear Technology Priorities Technology Leadership Commitments Drive green. Drive safe. Drive smart. SUSTAINABILITY GREEN SAFETY SAFE DESIGN SMART Leadership in fuel economy with every new or significantly refreshed entry More renewable, recycled materials Vehicle light weighting Leadership safety technology / feature content Achieve public domain targets and 3 rd party recommended buys Breakthrough features for family safety Design leadership on each new program Leadership in interior comfort / convenience, infotainment technology Global platforms with right proportions Improve emotional appeal Our leadership commitments around Quality, Green, Safe and Smart consistently guide our product development team priorities every day LEADERSHIP FOUNDATION QUALITY Drive quality. 24
Structural Castings An industry wide shift from stamped shock towers to cast aluminum components has begun. C2 Design Going forward... Typical Steel Design Die Cast Design 5-7 Stampings welded into one assembly with welds nuts and studs 1 Casting Expected benefits: Reduced component mass Increase local and vehicle level stiffness improved dimensional accuracy through part integration Efficient attachment integration elimination of brackets. Automotive aluminum castings and market trends Norberto F. Vidaña Market Intelligence Aluminum 25
Regulation Changes
Extrusions Front Header Extruded Applications on the F-150 A-Pillar / Roof Rail 1 Advantages Afforded by Extrusions: Freedom to place material where you need it Addition of internal ribs / reinforcements to improve the effectiveness of the design section Closed section without discrete connection points Front Header Section Case Study: Front Header Rocker Reinforcements Stamped to Extruded Lower Rad Support Shotguns 1 1 Additional geometry changes achieved through bending and hydro-forming processes Part Reduction: 3 to 1 Mass Reduction: 2.9 kg 27
Tailored Material Properties Rails were shortened for donor vehicle to provide correct vehicle proportions Mass of the vehicle increased over the donor vehicle Transition zone from soft to hard area Hard area Typical mechanical properties: R m = 1450 Mpa R e = 1100 Mpa Ɛ (A5) > 6% Typical mechanical properties: R m = 550 Mpa R e = 400 Mpa Ɛ (A5) > 20% Soft 28
Mixed Material BIW The Original Wood Structural Frames Aluminum Hood Steel Panels The Future... 29