“Formed extrusions & high strength sheets: latest aluminium innovations to meet passenger vehicle lightweight needs.” Presented at Automotive Circle’s Insight Edition @ Ford USA on September 24, 2015.
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Latest aluminium innovations to meet passenger vehicle lightweight needs
1. Formed extrusions & high strength sheets:
latest aluminium innovations to meet
passenger vehicle lightweight needs
Automotive Circle
Insight Edition @ Ford USA
September 24, 2015
4. Sheet or extrusions for Body-in-White structures?
Sheet and extruded components are complementary, allowing
the optimization of the performance/cost equation
4
Open/closed sections
Section type
Component thickness
Features & fasteners
Cycle time
Closed; easy to
implement.
Complex; multiple
chambers.
Constant along part.
Variable
Add cost
2 – 10 spm
Extruded components
Open; closed
sections require
assembly.
Multi-piece sections
necessary.
Variable along part.
Constant
Easy to implement
5 -25 spm
Sheet components
5. Constellium Automotive Structures
Full range of alloys and processes to accommodate the OEM needs
Major supplier of BiW structural parts in Europe and largest in North America
Crashboxes (CMS)
Bumper beams
Longitudinals
Engine cradle/Subframe
Cockpit carrier
Bumper beams (CMS) Add-on frames
Structural
components (BiW)
Ford F-150
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6. Design & manufacturing with extrusions
Account for extrusion tolerances in component design
Design tools for variable blank geometry and thickness !!!
Sections length of line are constant
Moving away from this paradigm
Maximize the ability to pierce and trim for machining reduction
Scrap removal during piercing of closed sections
Intensive use of FE forming analysis tools
Evaluate the influence of variations in input geometry
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7. Extrusion tolerances do not support BIW tolerances
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Absorb extra tolerance in the assembly process
Calibrate important sections
9. Extrusion post-processing summary
Product design w/ extrusion allows the use of closed, variable
thickness sections
Maximize through thickness bending
Several possibilities outside of hydroforming
Forming simulation tools are readily available
Forming tools to account for incoming cross section and thickness
variations
Required aging treatment after forming, tailored to performance
requirements
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10. The right alloy for each application
Alloy
Strength
Shape
Complexity
C20
C22
C24
C28/
6082
HSA6
YS 200 6 YS 220 MPa YS 240 MPa YS 280 MPa YS 370 MPa (400 UTS)
Crush Strength
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11. High strength crash resistance alloy – C28
C28 extrude beam
Bender mandrel r=0.4 mm
Yield stress: 280 MPa
UTS: 310 MPa
End Forming of C28 extrusion
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12. Ultra-high strength 6xxx extrusion- HSA6
Hollow
sections
YS
(MPa)
UTS
(MPa)
A50
(%)
Bending
(°)
HSA6 370-400 400-430 10 90
Novel and proprietary high
strength 6xxx alloy
With UTS 400 Mpa
Excellent corrosion resistance
Application to CMS: bumper
mass down by 15%
Key advantages in recycling
compared to 7xxx alloy
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13. Constellium’s BiW sheet portfolio
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FORMALEX®
Forming optimized
SURFALEX®
Perfect surface with excellent hemming
SECURALEX®
Crash crushable alloy for
structural parts
STRONGALEX®
High Yield Strength
SECURALEX®P5/P6
Pedestrian Safety alloy
SECURALEX® HS
High Strength Crash Crushable
FORMALEX® PLUS
Extra formability for complex shapes
5754, 5182
SURFALEX ® HS
Perfect surface with High Strength.
SURFALEX ® HF
Perfect surface with High Formability.
14. Body-in-White sheet key driver: no compromises
SAFETY
LIGHTWEIGHTINGSTYLE
DESIGN
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Elongation
Isotropy
Strength
Work
hardening
Energy
absorption
Thermal
stability
Paint bake
response
Ductiliy
Corrosion
resistance
Hemming
Roping
Character
lines
15. Development of high strength structural alloys
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Standard Today High Strength Ultra High Strength
YS [MPa]
Formalex®Plus
Formalex®
6016-X
6016-DRX/RSX
Strongalex®
Ultralex®V1
Ultralex®V2
Strongalex®Plus
0 200 400 600 800 1000 1200 1400 1600 1800 2000
Steel equivalent
by density ratio
7000-series
6000-series
5000-series
1000 /
3000 /
8000 -series
16. High strength 6xxx aluminium alloys
* 2% + 20’@185°C
6xxx-alloys offer unmatched corrosion
resistance for cosmetic, intergranular- and
stress corrosion cracking
They are formable and joinable by
conventional mechanical joining and welding
joining techniques
They are ideally suited for uni-alloy concepts
and closed loop recycling
Strength Ductility Status
YS @T4 YS @PB* YS @T6 A80% @T4
Securalex® ~100 ~180 250 25 Serial
Strongalex® ~140 ~260 300 25 Serial
Strongalex®Plus ~160 ~300 330 23 Industrial trials
Strongalex®380 ~170 ~310 350 23 Industrial trials
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17. Ultra high strength 7xxx solutions: Ultralex®
Ultralex® v1: complies to AA7075; long experience and reference
data (processing, corrosion) coming from aerospace applications.
Ultralex® v2: still in development; target is highest strength with
excellent stress corrosion performance and easy implementation in
hot stamping lines
Strength Ductility Status
YS @T7 YS @T6 Rm @T6 A80 @T6
Ultralex® v1 480 MPa 530 MPa 580 MPa 15%
Industrial
available
Ultralex® v2 560 MPa 620 MPa 675 MPa 13% Lab trials
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18. Forming technologies for Ultralex®: hot forming
Part
Picture
B-pillar trials at Constellium
Blank heating during few minutes at SHT temperature
Transfer
Stamping in cold dies
Press quenching (die closing maintained)
Total forming cycle time ~20 seconds
Heat-up time: 8 minutes per batch
Ultralex v1 & Ultralex v2
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19. Forming technologies for Ultralex®: hot forming
Thickness
white= experimental
red = numerical
1.94/
2.0
1.52/
1.72
1.62/
1.7
1.94/
1.91
1.62/
1.59
1.79/
1.81 1.81/
1.83
1.85/
1.891.97/
2.0
1.89/
1.95
1.84/
1.9 1.99/
2.0
1.66/
1.74
1.61/
1.54
1.67/
1.7
Simulations of hot forming
B-pillar trials with Autoform
thermosolver
Consistent with experimental
results
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20. Main concern for 7xxx-series structural alloys is to be safe from
catastrophic stress corrosion cracking failure in service.
We test materials under multiple stress loading modes beyond plastic
yield and in different corrosive environments to ensure immunity to SCC
or hydrogen embrittlement in service.
Ultralex® copper containing 7xxx-series alloys in overaged tempers
provide robust resistance in these tests.
Ultra high strength 7xxx-series alloys: corrosion
U-bend test specimen,
2-3% plastic deformation
Ultralex®v1. No failure
ASTM G85-A2 640 hours
Reference Alloy. Fully cracked after
167 hours ASTM G85-A2
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21. New Constellium-UACJ plant in Bowling Green, KY
Joint venture between Constellium and UACJ to meet the growing
demand for automotive body sheet in North America.
Devoted to aluminum automotive body sheet
240,000 square feet
Full portfolio of 5xxx and 6xxx alloys
In-line pretreatment and lubrication
Maximum width: 2200mm
Maximum gauge: 3.2mm
Separate coil completion line
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22. Summary
Sheet and extruded components will continue to share the car
design space in Body-in-White construction.
Advancements are focused on extending the strength spectrum to
achieve further weight savings.
Constellium has established a joint venture with UACJ for auto
body sheet in North America.
A new greenfield plant in Bowling Green, Ky., will start
production in 2016.
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