Forta H-Series - New MnCr material for lightweight seating ...

Forta H-Series New MnCr materials for lightweight seating construction

Claire Heidecker

Outokumpu EMEA GmbH

11th International Conference Innovative Seating

February 16th, 2016

2

Agenda

1. Rising expectations in automotive construction materials

2. Characteristics of the new Forta H-Series

3. Processability of the new Forta H-Series

• Forming

• Joining

• Surface technology / corrosion behavior

4. Application examples

5. Summary

Sourc

e:

Johnson C

ontr

ols

, P

ress r

ele

ase a

t th

e I

AA

2013

„Innovative m

eta

l com

ponents

for

vehic

le s

eats

“

2/15/2016 Forta H-Series / C. Heidecker / 11th International Conference Innovative Seating 3

Rising expectations Lightweight vs. safety

Material characteristics Expectations Processability Application Summary

Source:

http://www.euroncap.com/en/vehicle-safety/the-ratings-explained/adult-

occupant-protection/side-mobile-barrier/

CO2 emission limits for passenger cars

Source:

ICCT

• High strength and high formability

• High energy absorption and crash

resistance

• High passenger safety

• New design options

• New lightweight possibilities

The new Forta H-Series Energy absorption potential and crash resistance


Drop height h = 4.0 m

Drop weight m = 433 kg

Fall velocity v0 = 30.73 km/h

H1000 22MnB5


• Material names:

Forta H500 / H800 / H1000

• Alloying system Mn – Cr – Fe

• Nickel-free material

• Fully austenitic microstructure

• Uncoated delivery condition

• Due to their alloy system MnCr

materials must be painted in exterior

applications

The new Forta H-Series A new austenitic material group with ultra-high strength (UHSS-grade)



Material

Yield

strength

Rp0.2 [MPa]

Tensile

strength

Rm [MPa]

Elongation

at fracture

A80 [%]

typ. typ. typ.

Forta H500 530 900 51

Forta H800 800 1000 31

Forta H1000 1000 1200 13

• Material names:

Forta H500 / H800 / H1000







applications




• Material names:

Forta H500 / H800 / H1000







applications




• Material data sheets available for 40

strips

• Material listed in the Register of

European Steels as 1.4678

• Simulation data available for forming

and crash

• Determination of material

characteristics according to

SEP1240/1245/1220 and baseline

investigations ongoing

The new Forta H-Series Where do we stand today?




Processability of the Forta H-Series Forming behavior and hardening effect


Material shows off significant

work hardening – highest

effect in the largest section Hydroformed Porsche dashboard cowl,

H500 in t = 1.6 mm

• Work hardening due to thickness

reduction

• Tensile test (transverse to rolling

direction) with step rolled profiles

• Maximum cold-rolling degree

~ 67 %

Processability of the Forta H-Series Hardening effect due to cold-rolling



Processability of the Forta H-Series Quasi static force transmission in welded condition


• High and homogeneous force

transmission in every direction of load

• Ductile behavior of the weld spot

• Similar force transmission level for

H500, H800 and H1000

KS2 tensile

specimen

(LWF Paderborn)

Spot-weld

diameter

d = 7.44 mm


Processability of the Forta H-Series Material behavior in the weld nugget and the heat affected zone


• Measurement of the Vickers hardness

through a spot weld H800 similar,

t = 1.5 mm

• Typical austenitic softening in the heat

affected zone, different from ferritic

hardening effect and embrittlement

• Material in annealed condition in the

weld nugget (with Rm ≥ 900 MPa)


Processability of the Forta H-Series Crash behavior of welded profiles


• Excellent forming behavior in dynamic

three point bending test

• No crack formation / material failure in

the base material as well as in the

welded zones

• High energy transmission and

absorption even in the welded areas


TIG tailored blank

H800 / H1000 spot

welded on a

HC340LA + ZE

locking plate

Drop height h = 2.5 m

Drop weight m = 57.9 kg

Fall velocity v0 = 24.5 km/h

Processability of the Forta H-Series Material behavior in the weld seam and the heat affected zone


• The hardening effect of the H-Series

primarily takes place in the ductile

welded zones

o This results in a high crash

performance with welds close to

the base materials strength level

o The welded zone is not the weak

point of the system


Area of

hardness

measurement

Processability of the Forta H-Series Paint adhesion / corrosion protection system


• CrxOy passive layer under cathodic dip

coating reduces corrosive disbonding

after damage of coating

• Paint disbonding / stone chipping value

better than zinc coated reference material

• Additional improvement by abrasive

blasting capable of being integrated in

material manufacturing process

• Differences between Forta H500, H800

and H1000 are insignificant


Stone chipping value: 1,5

Lattice cut value: Gt0-1 Good r

esults a

t

lattic

e c

ut

(DIN

EN

IS

O

2409)

Good r

esis

tance a

gain

st

sto

ne c

hip

pin

g

(DIN

EN

IS

O 2

0567

)

H500 with

cathodic dip coating

after 10 cycles

VDA 621-415

alternating climate test


Application examples


Thin and complex

forming parts

Crash relevant

components Tube structures

Profile structures /

innovative manufacturing



Source:

http://media.daimler.com/dcmedia

„Mercedes-Benz C-Klasse Limousine“

Application examples Crash relevant components

A- and

B-pillars

Rocker rail

Channel

Side impact

protection Crashbox

Bumper

Cross members

Forta H-Series with their

• high strength

• active energy absorption potential

• excellent processability

Enable

• a high passenger safety

• an excellent direct and indirect lightweight potential





Application example:

Porsche

Roll-over protection

Application examples Tube structures


• excellent formability

• good weldability

Enable

• a large scale industrial production of tube components with cost efficient manufacturing technologies

• a high energy absorption potential

• the reduction of wall thicknesses



Application examples Profile structures / innovative manufacturing ways

Source:

Welser Profile GmbH

Product data sheet


Porsche

Hydroformed dashboard cowl


• high strength and ductility

• austenitic microstructure with strain-hardening induced by twinning

Enable

• the use of hydro- or roll-forming

• the production of components with a high stiffness and crash performance

• the reduction of wall thicknesses / functional integration




• high strength

• excellent formability

Enable

• the fabrication of complex components with low wall thicknesses (≤ 0.6 mm) under retention of a high strength


TechROi

Fuel tank

Application examples Thin and complex forming parts

Summary


Material is commercially available: t = 0.5 up to 4.0 mm, b = 1,250 mm



Summary


Possibility for complex forming and innovative production processes

Material > 80 % manufactured by recycled materials and 100 % recyclable

High direct and indirect lightweight potential

Material is commercially available: t = 0.5 up to 4.0 mm, b = 1,250 mm

Forta H-Series for more security, higher crash absorption, high formability and

lightweight potential

Active energy absorption and excellent crash resistance as sheet and tube

construction, even in welded areas

Thank you for your attention

Claire Heidecker

Outokumpu EMEA GmbH

11th International Conference Innovative Seating

February 16th, 2016

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