7/29/2019 Volvo Fredin
1/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
Future materials for body structure applicationsFuture materials for body structure applications
Kaj Fredin, Advanced Body Engineering Volvo Car Corporation
Volvo Car Advanced Body EngineeringVolvo Car Advanced Body Engineering
YesterdayYesterday--TodayToday--TomorrowTomorrow
OptimalOptimal
material MIXmaterial MIX
OptimalOptimal
material MIXmaterial MIX
Advanced
BodyEngineering
7/29/2019 Volvo Fredin
2/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
Process investments Cost Technology step Commonality
Comfort Safety Reliability Cost EnvironmentFuel
consumptionDesign
Customer
satisfaction
Stiffness
Strength
Panel fit Weight Flexibility
Surface
finish
Material
Structure
Joint
Complete vehicle Properties
Car Body Properties
Basic Body Technology Parameters
Durability
Colour
Corrosion
protection
Drivers & constraintsDrivers & constraints
7/29/2019 Volvo Fredin
3/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
FactsFacts-- Trends & Wanted PositionTrends & Wanted Position
! !
168gCo2/km ! 145gCo2/km !
2008 2012Mainly carbon steel, moderate level ofcontinuous joints in conventional uni-body
produced in current process
Time850 S80 S60 XC90 S40+ S80+ XC90+
?
Necessary
Technology
Shift
2000 2006 2009
Wanted Position
2009
Total Passive
Safety Performance
Projected body weight
Cost
The Steel Era
! !
168gCo2/km ! 145gCo2/km !
2008 2012
! !
168gCo2/km ! 145gCo2/km !
2008 2012Mainly carbon steel, moderate level ofcontinuous joints in conventional uni-body
produced in current process
Mainly carbon steel, moderate level ofcontinuous joints in conventional uni-body
produced in current process
Time850 S80 S60 XC90 S40+ S80+ XC90+
?
Necessary
Technology
Shift
Necessary
Technology
Shift
2000 2006 2009
Wanted Position
2009
Total Passive
Safety Performance
Projected body weight
Cost
Total Passive
Safety Performance
Projected body weight
Cost
The Steel Era
7/29/2019 Volvo Fredin
4/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
The average weight development corresponds to an annual increase of fuel consumption of 0,052l/100km
(corresponding to approximately 1,2 gCO2/km). The weight increase results from increased requirements
in NVH, safety, convenience, driving & up-sizing
Body & trim weight
contribution is currently50-53% of the total car
weight. The average
weight of the car has
increased at a rate of 10kg
per annum, platform to
platform
Weight developmentWeight development
7/29/2019 Volvo Fredin
5/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
P1X54% HSS
23% >HSS
XC9057% HSS
21% >HSSS80
36% HSS
2% >HSS
85036% HSS
0% >HSS
74015% HSS
0% >HSS
2400% HSS
0% >HSS
% HSS(Rm>340MPa)
% EHSS>(Rm>600MPa)
S8059% HSS
25%
>HSS
0
10
20
30
40
50
0
10
20
30
40
50
Approximate values
Steel sheet development within Volvo CarSteel sheet development within Volvo Car
7/29/2019 Volvo Fredin
6/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
Tensile Strength, Rm (MPa)
Yield Strength, Re (MPa)
max170-280 min220 min280 min400
max270-390 min340 min600 min800MS HSS EHSS UHSS
Rephos
HSLA
DP
Rephos
HSLA
DP
HSS: HSLA & RephosStandard qualities for high strength
steel sheets. Rephos higher formability
compared to HSLA.
HSS/EHSS: DP-steelsUsed for reinforcements and safety
components for high load capacity and
balanced weight impact, e.g. B-pillar
reinf., roof bow, sill reinf.
UHSS: Boron-steelsSimilar applications as DP-steels andfor extreme load cases, e.g. bumper
beams, B.pillar reinf., roof bows.
Boron steel
Boron steel
HighHigh StrengthStrength SteelSteel Sheets, EHSSSheets, EHSS within Volvo Car Stdwithin Volvo Car Std
(Rpmin >220 Mpa, Rmmin >340 Mpa)
7/29/2019 Volvo Fredin
7/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
Material GradeDistribution (%-weight)
HSS
EHSS UHSS
HSS
EHSS UHSS
XC90XC90XC90
46%
31%
20%3%
1%
47%
32%
13%7%
S40S40S40S40 new Volvo patented front end, same concept
as XC90. Frame of beams working in
compression and tension instead of bending.
Rephos
DP600 Boron
Volvo Car state of the art steel body structuresVolvo Car state of the art steel body structures
Al
MS (Rp
7/29/2019 Volvo Fredin
8/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
Not taking strain hardening into account = over dimensioning !Not taking strain hardening into account = over dimensioning !
virgin
2% strain5% strain
320
500
650
Plastic strain
Trues
tress(MPa)
DP600, Stress-Strain for different pre-strain levels
virgin
2% strain5% strain
320
500
650
Plastic strain
Trues
tress(MPa)
virgin
2% strain5% strain
320
500
650
Plastic strain
Trues
tress(MPa)
DP600, Stress-Strain for different pre-strain levels
virgin
2% strain5% strain
320
500
650
Plastic strain
Trues
tress(MPa)
DP600, Stress-Strain for different pre-strain levels
virgin
2% strain5% strain
320
500
650
Plastic strain
Trues
tress(MPa)
virgin
2% strain5% strain
320
500
650
Plastic strain
Trues
tress(MPa)
DP600, Stress-Strain for different pre-strain levels
The ExtraThe Extra HighHigh StrengthStrength SteelSteel challengechallengeLesson learned, DP600 front side member application S40
7/29/2019 Volvo Fredin
9/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
The suppliers different material concepts,
process ability & scatter are concerns
Continue reducing weight with Advanced High Strength SteelsContinue reducing weight with Advanced High Strength Steels
Reaching an additional 5% cost efficient weight reduction
DP600
Boron
steel
MS-W1200:
DP600
Boron
steel
MSW 1200
DP600
Boron
steel
MS-W1200:
DP600
Boron
steel
MSW 1200
MSW 1200: Martensitic hot rolled steel
CP 800: Complex phase hot rolled steel
Trip 700: Transformation Induced Plasticity cold rolled steel
DP: Dual phase cold rolled steels
Today
Tomorrow
>86,5Rmmin >800UHSS>1814Rmmin >600EHSS
Rmmin >380-420
Rmmin >340HSS
(%)(%)(Mpa)
7/29/2019 Volvo Fredin
10/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
And then ?And then ?Austenitic stainless steels
Combining high strength with excellent formability !!
Driver: Enabling weight reduction 1 step
further than high strength steel. Lower mix-
material risk compared to aluminium
Target: 40% weight reduction at lower
cost/save kg than Aluminium.
Driver: Enabling weight reduction 1 step
further than high strength steel. Lower mix-
material risk compared to aluminium
Target: 40% weight reduction at lower
cost/save kg than Aluminium.
B pillar section;
Sill
B pillar
Roof bow
Cant rail
B pillar section;
Sill
B pillar
Roof bow
Cant rail
Front section;
Bumper beam Crash box
Side member lower
Radiator beam
Spring-
tower
Front section;Front section;
Bumper beam Crash box
Side member lower
Radiator beam
Spring-
tower
Bumper beam Crash box
Side member lower
Radiator beam
Spring-
tower
7/29/2019 Volvo Fredin
11/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
Other light weight body structure materialsOther light weight body structure materialsInteresting or not ?
Fibre reinforced polymersi.e. Ip-structure, spare wheel well, parcel shelf
Sandwich materialsi.e. floor panels, roof, hood
Die cast magnesiumi.e. Ip-structure, SIPS-box
Aluminium (extrusion, castings & sheets)for various structural applications
Weight
P.Safety
Cost
Weight
P.Safety
Cost
Weight
P.Safety
Cost
Weight
P.Safety
Cost
Weight
P.Safety
Cost
Weight
P.Safety
Cost
Weight
P.Safety
Cost
Weight
P.Safety
Cost
PolymerMetal
JointsJoints
StructureStructure
MaterialsMaterials
7/29/2019 Volvo Fredin
12/12
Uddeholm Automotive Seminar 2005-02-09
Advanced
BodyEngineering
Future materials for body structure applicationsFuture materials for body structure applications
Magnesium
Multi phase steelsStainless steels
Continuousjoints
Structural
foams
Boron Steels
Aluminium
Fibre reinforced
polymers
Multi material usage
with high degree of
continuous joints in
upgraded structure
produced in a
modified process
Multi material usage
with high degree of
continuous joints in
upgraded structure
produced in amodified process
The future body structureThe future body structure
Improving passive safety & reducing weight at minimum cost
Properties
In balance !
Weight
Cost
Properties
In balance !
Weight
Cost
Top Related