Advanced High Strength Steel Technology in the Ford 500 .../media/Files/Autosteel/Great Designs...

Advanced High Strength Steel Technology in the Ford 500 and

Freestyle

Michael J. LeeFord Motor Company

March 9, 2005

w w w . a u t o s t e e l . o r g

09-MAR-2005 Ford Confidential

GDIS Presentation Michael J. Lee

2

Agenda

• Overview of Products

• Presentation Scope / Purpose

• Assumptions / Challenges

• Materials and Application

• Formability and Welding Lessons Learned

• Conclusions



3

Ford 500



4

Ford 500

“Redefining the North American sedan is a tall order…We took a look at the attributes that make crossovers popular – like high-package ‘command’ seating – and sought to deliver some of those qualities in a sedan. While the industry tries to create new car-based crossovers, the Ford Five Hundred stands alone as the first crossover-based car.”

Phil Martens Group Vice President Product Creation Ford Motor Company



5

Ford Freestyle



6

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 CreationFord Motor Company



7

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 2nd

and 3rd row seats folded down• Unparalleled convenience and

storage• Most flexible/versatile interior• Effortless entry and exit• AWD for safe and confident

driving.



8

Agenda






• Conclusions



9

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



10

Agenda






• Conclusions



11

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.



12

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



13

Agenda






• Conclusions



14

Stress/Strain curves

Engineering Strain (%)

0 10 20 30 40 50

Eng

inee

ring

Stre

ss (M

Pa)

0

200

400

600

800

Mild SteelHSLA (50F) DP600TRIP600



15

Dual Phase vs. HSLA

Relative Performance

DP600 HSLAFormability ++ +Weldability ++ +++Fatigue +++ +++Energy Absorption +++ ++Bake Hardening +++ +Work Hardening +++ +



16

Dual Phase vs. HSLA

Strength

Component Material Strength

0

100

200

300

400

500

600

HSLA350/450

DP350/600

Yield Strength

Sheet YSWork-HardeningBake-Hardening



17

Material Usage by Mass on Ford 500

14%

12%

0%15%

59%

HSLA250

HSLA350

HSLA550

DP600

Mild Steel



18

Ford 500

Green: HSLA 250Blue: HSLA 350Yellow: HSLA 550Red: DP 600Purple: Inner: Top DP600 / Bottom

HSLA 250Outer: Top DP600 / Bottom Mild Steel



19

Ford 500

Green: HSLA 250Blue: HSLA 350Yellow: HSLA 550Red: DP 600Purple: Inner: Top DP600 /

Bottom HSLA 250Outer: Top DP600 / Bottom Mild Steel



20

500 Safety Success – Frontal

5 – Star for Driver and

Passenger!!!



21

Ford 500 – Load Path - Frontal

TWB HSLA Front RailDP600 Dash xmbrsDP600 Y-Brace

DP600 Side Member

HSLA Tunnel



22

Ford 500 – Load Path -Frontal

HSLA Shotguns/Rails

HSLA Cowl Sd Inr Pnl

Upper / Lower Load Path



23

500 Safety Success – Side Impact

5 – Star for Front Seat and Rear Seat

without Side Airbags!!!!!



24

Ford 500 – Load Path – Side Impact

TWB DP600 B-Plr Inr/OtrHSLA 550 Ctr Roof BowHSLA CrossmbrsDP600 Side Mbr



25

Ford Freestyle





26

Ford Freestyle





27

Ford Freestyle – Bottom View

Unique Reinfs for 2nd

Row Seats vs. 500



28

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



29

Body Stiffness Vs. Competition

CD338 ADV

M azda 6M azda 6 Ford D219 CP1

Ford D258 CP1

M ercury Sable

Audi A8Toyota Camry

Honda Accord

Ford TAURUS

Lexus RX300

BM W 328i

BM W X5

Toyota Avalon

Toyota Celica

BM W 330i Coupe

Toyota Camry

Toyota Highlander

Lincoln LS

M azda 6

Honda Civic

0

4000

8000

12000

16000

1992 1994 1996 1998 2000 2002 2004 2006 2008

MY

N/m

m

500Freestyle



30

Agenda






• Conclusions



31

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



32

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.



33

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.



34

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 sub-assembly will increase the number of non-pryable welds.



35

Agenda






• Conclusions



36

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



37

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



38

Acknowledgements

• Paul Schurter / Sean Martin - Dofasco

• Todd Mueller – Ford Body Structures

• Ted Coon – Ford VOGO – Welding

• Dr. Don Jordan – Ford Materials



39

Thank you for your Attention.

Please feel free to contact me at:

[email protected]

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