GF Automotive AG
Lightweight Activities at Georg Fischer
Workshop:
Functional and Innovative Lightweight
Concepts and Materials for HEVs
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking4
Georg Fischer
Corporation
Foundation: 1802
Headquarter: Switzerland
124 companies in 32 countries
Listed (Swiss stock exchange)
For over 200 years independent
Employees: 14.000
Sales 2013: CHF 3.8 billion
Georg Fischer AG: Three strong Divisions
GF Piping Systems
GF Automotive
GF Machining Solutions
Facts & Figures
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking5
Georg Fischer
Three strong Divisions
40% GF Lightweight Solutions
37% GF Piping Systems
23% GF Machining Solutions
100% = CHF 3,77 billion ~ EUR 3,06 billion
Overview 2014 | 03/2014 | GF Automotive6
Georg Fischer
Piping Systems
Your solutionGF Piping Systems is a leading
supplier of piping systems made of
plastics and metal
Overview 2014 | 03/2014 | GF Automotive7
Georg Fischer
Automotive
Lighter FutureGF Automotive is a leading global
supplier of iron and light metal cast
components for the automotive
industry and industrial applications.
Overview 2014 | 03/2014 | GF Automotive8
Georg Fischer
Machining Solutions
Keeping promises GF
Machining Solutions’ electric
discharge, high-speed milling and
laser texturing machines, along with
automation solutions, make it the
world’s leading provider
Main purpose of the foundation is
the financial support of projects
related to the improvement of
access to clean drinkable water
for human beings
Founded in 2002
Over 110 Projects in
over 50 Countries
GF Automotive has injected over
CHF 8 million
Overview 2014 | 03/2014 | GF Automotive9
Georg Fischer
Clean Water Foundation
EUR 1.22 Bill.Sales
4 940Employees
9 Production Locations
Passion for your Lighter Future
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking11
GF Automotive
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking12
GF Automotive
Segments & Products
Iron: 62%
~ 3000 Products ≙ 100 000 000 Parts
Light Metal 38%
Overview 2014 | 03/2014 | GF Automotive13
GF Automotive
Product Segment – Passenger Cars
Powertrain
Chassis
Body / Structure
Overview 2014 | 03/2014 | GF Automotive14
GF Automotive
Product Summary – Passenger CarsAverage Production per Year
> 1 300 000
> 9 000 000
> 15 000 000
> 3 700 000
> 450 000
> 1 300 000
Chassis
Axle
Steering
Brake
Subframe
Powertrain
Engine
Transmission
Drive Train
Body / Structure
Interieur
Exterieur
Overview 2014 | 03/2014 | GF Automotive15
GF Automotive
Product Segment – Comm. Vehicles
Powertrain
Chassis
Frame / Cab
> 1 750 000 > 450 000 > 300 000
Overview 2014 | 03/2014 | GF Automotive16
GF Automotive
Product Summary – Comm. VehiclesAverage Production per Year
> 2 500 000 > 200 000 > 700 000
Powertrain
Engine
Transmission
Drive Train
Chassis
Axle
Steering
Brake
Frame/ CabStructure-mounting parts
Overview 2014 | 03/2014 | GF Automotive17
GF Automotive
Product Segment – Industrial Application
Energy & Engine
Industry &
Consumer
Offroad
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking18
GF Automotive
Global Locations
Headquarter and
R&D
Schaffhausen
Countries delivered
by GF Lightweight Solutions
LMDC
Werdohl
Altenmarkt
Herzogenburg
Production Site /
Headquarter
LMDC
Suzhou
Iron Casting
Kunshan
Cooperation
Grede
Cooperation
Riken
Sales Office
Sales Office
Yokohama
Seoul
Cooperation
Iron Casting
Mettmann
Singen
Herzogenburg
Leipzig
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking19
GF Automotive
Added Value: It does not stop with a casting
Joining
Machining Heat TreatmentCasting
Coating Assembly
Downsizing
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking20
GF Automotive
Future Drivers for Lightweighting
CO2 Footprint
E- Mobility
Material Development
Design
GF Automotive
Development Competence
Overview 2014 | 03/2014 | GF Automotive21
State-of-the-art processes:
From design phase to serial
production
Virtual Development:
The complete
component development
from material selection
to casting process is
simulated, validated and
continuously improved
GF Automotive
Material – Optimal Characteristics
Overview 2014 | 03/2014 | GF Automotive22
Maximize material
advantages:
GF Automotive´s R&D
Department develops state-of-
the-art alloys and maximizes
the specific characteristics of
iron, aluminum and
magnesium consequently
Material
Des
ign
Process
Va
lid
ati
on
GF Automotive
Design – Ideal Shapes
Overview 2014 | 03/2014 | GF Automotive23
Using degree of freedom:
Virtual tests, simulations and
analyses shorten
development time and reduce
costs for real test runs. In
addition it is possible to define
dimensions, visualize shapes,
anticipate noise and
vibrations, simulate casting
processes and calculate the
lifetime of components.
Material
Des
ign
Process
Va
lid
ati
on
GF Automotive
Process – Precise Procedures
Overview 2014 | 03/2014 | GF Automotive24
We know how to cast:
Our knowledge in innovation
and light weight construction
requires a continuous
evolution of proven
procedures. GF Automotive
relies on iron-sandcasting and
aluminum and magenesium
die-casting technologies to
cast products in best shape.
Our engineers will find the
optimal process for every part.Material
Des
ign
Process
Va
lid
ati
on
GF Automotive
Validation – Testing Materials and Parts
Overview 2014 | 03/2014 | GF Automotive25
Testing functions:
Our conviction, that our
products guarantee the
expected advantages, relies
on our accredited testing
laboratory. By state-of-the-art
testing methods,
GF Automotive validates in-
house and other parts already
during development phase.
Material
Des
ign
Process
Va
lid
ati
on
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking27
GF Automotive
Casting or Carbon Composites?
Repair
Herstellung
Recycling Material Cycle
Lower Energy Consumption
Resistance
Costs
Production
Lighter
Corrosion Resistance
Repair
Recycling
CarbonIron
Aluminum
Magnesium
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking28
GF Automotive
Material Comparison
GJS 400-15
GJS 450-10
SiboDur
700-10
Aluminum Magnesium Carbon
Fiber
Tensile
Strength Rm
(N/mm2)
Min. 400-450 Min. 700 277-338 217.5-230 3530-4560
0.2%-Yield
Stress Rp0,2
(N/mm2)
Min. 250-310 Min. 440 142-196 112.5-155 -
Elongation
(%)
Min. 10-15 8-12 3.5-12.5 3.5-10 1.1-1.5
Young’s –
Modulus
(kN/mm2)
175 175 72-77 43-45 230-395
Density
(g/cm3)
7.1 7.1 2.6-2.7 1.8 1.8
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking29
GF Automotive
Lightweighting Potential
Source University of Cambridge
Weight Reduction
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking30
GF Automotive
Repair Job
Metal Repair
Carbon Fiber Repair
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking31
GF Automotive
Production Chain of Carbon Fiber and Magnesium
Carbon Fiber
Magnesium
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking32
Carbon Fiber Production Chain
crackingammoxidation
polymerisationoxidation
carbonisationtake effect stack preform
assembly use
crude oilpropylene
acrylonitrileprecursor
oxidised fibercarbon fiber
carbon fabricspackage
mouldCF part
scrap
recycle
plastics
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking33
GF Automotive
Magnesium Production Chain
dolomite
sea water
recycle
meltingelectrolyse
high-pressure casting
machiningassembly
use
finished product
raw magnesium
liquid magnesium
casted product
part
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking34
GF Automotive
Manufacturing Climate Balance Sheet
CO2 Emissions
Source University of Cambridge
Due to pidgeon
process
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking35
GF Automotive
Manufacturing Energy Consumption
Energy Consumption
Source University of Cambridge
Energy Consumption
Due to pidgeon
process
36
GF Automotive
Emission over Life-Cycle
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
Change of Perspective: Break-Even
Source: VW, University of Cambridge
Break Even:
0 km High Strength Steel
90.000 km Aluminum
120.000 km Magnesium
170.000 km Carbon Fibre
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking37
GF Automotive
Availability
Carbon fiber:
Uses polyacrylonitrile
Magnesium:
8th abundant element
in earth’s crust
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking38
Carbon Fiber Metals
GF Automotive
Recycling
Fully recyclable
Used in new alloys
Used as a mixture in new alloys
Recyclable?
At least downcycling or scrap
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking39
GF Automotive
Cost Comparison
Costs per Part (in % of Steel)
Steel
Aluminum
Magnesium
Carbon
100
130
155
570
Source: McKinsey&Company, Magnesium own Research
University of Cambridge
Up to 3 times higher costs for carbon fibre
With new precursors and technological progress improving production
processes, a decrease of almost 30% in the global cost of composites is
expected between now and 2020
Today
Tomorrow
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking40
GF Automotive
Lightweighting Potential
Source University of Cambridge
Weight Reduction
41
GF Automotive
Substitution of Sheet Metal Constructions
Weight Reduction
Casted aluminum compared to
steel sheet assembly out of 10
parts up to 45% less weight
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking42
GF Automotive
Carbon Fiber vs. Aluminum
Source: BMW AG
100% Carbon?
43
GF Automotive
Substitution of Sheet Metal Constructions
Weight Reduction
Seat frame in casted
Magnesium up to 30% less
weight than metal sheet
assembly
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking44
GF Automotive
Carbon Fiber vs. Magnesium
- 30% Weight Reduction compared to
conventional Steel-based Designs
Carbon Fiber Magnesium
- 30% Weight Reduction compared to
conventional Steel-based Designs
Source BASF
45
GF Automotive
Bionic Design
Weight reduction
Iron steering knuckle up to
35% less weight through
bionic design
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking46
GF Automotive
High Design Freedom for Castings
Front Steering Knuckle
Carbon
- 40%
Iron
- 35%
++
++
+
-
++
++
Iron / Steel
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking47
GF Automotive
Material Strengths and Weaknesses
Costs
Recycling
Energy Consumption
Weight Reduction
Repair
Strength +
+
o
+
+
+
o
o
-
++
+
o
++
--
-
++
--
--
Aluminum Magnesium Carbon
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking48
GF Automotive
Material Comparison
Weight per Part
In % of Steel
Costs per Part
In % of Steel
Steel
Aluminum
Magnesium
Carbon
100
60
50
50
Steel
Aluminum
Magnesium
Carbon
100
130
155
570
Source: McKinsey&Company, Magnesium own Research
Production
Recycling Costs
Repair
Material CycleMaterial
Serial Production
Energy Consumption
SustainabilityProcess Reliability
Process Reliability
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking49
GF Automotive
Which Material?
Carbon
Aluminum Magnesium
Steel
(Quelle: Prof. Dr. Claus Mattheck)
Principle
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking51
Start
Topological Optimization
CAD
Bionic Design
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking52
Bionic Design
-12,5 %
Before
GJS 700
7,2 kg
After
SiboDur® 700
6,3 kg
53
Bionic Design
Weight Reduction
Differential housing in iron
casting up to 15% less
weight than predecessor
through bionic design
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
54
Substitution of System Parts
Weight Reduction
Crossmember, completely
casted in iron has 17% less
weight than combined
assembly out of steel sheet
and iron
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
55
Substitution of Sheet Metal Constructions
Weight Reduction
Inno Door Frame in casted
Aluminum up to 40% less
weight than metal sheet
assembly
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking57
Product Samples in Series: Maserati Quattroporte
Inner Door Frame
Alloy: AlMg5Si2Mn
Weight : 4,8 kg (- 40%)
Copyright by Maserati
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking58
Product Samples in Series: Porsche Panamera
Cam Cover V6 (1-3 and 4-6)
Alloy: AE 44 / MgAl4RE4
Weight : 1,36 / 1,2 kg (- 44%)
Copyright by Porsche
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking59
Product Samples in Series: Porsche Panamera
Oil Separator V6/V8
Alloy: AM50 / MgAl9Zn1
Weight: 0,25 / 0,18 kg (-28%)
Copyright by Porsche
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking60
Product Samples in Series: Porsche Panamera
Oil Sump V6 2WD
Alloy: AE 44/MgAl4RE4
Weight: 4,6 kg (- 47%)
Copyright by Porsche
Product Samples in Series: Porsche Panamera
Engine Front Cover
Alloy: AE 44/MgAl4RE4
Weight: 2,6 kg (- 47%)
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking61
Copyright by Porsche
Product Samples in Series: Opel Cascada
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking62
Copyright by Opel
Convertible Roof Top
Alloy: AM50HP
Weight: 2,2 kg (- 40%)
Anchor points for counter ropes
without processing
Minimum wall thickness 1,2 mm
Product Samples in Series: Smart fortwo
Instrument Panel Crossbar
Alloy: MgAl5Mn
Weight: 2,4 kg
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking63
Copyright by Smart
Product Samples in Series: BMW X3
BMW X3
Box Swing Arm
Alloy: MgAl9Zn1 (AZ91)
Weight: 0,8 kg (-35%)
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking64
Copyright by BMW
Product Samples in Series: Porsche Macan
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking65
Copyright by Porsche
Engine Front Cover
Alloy: AE44
Weight: 2,6 kg (- 40%)
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking66
E-Mobility – New Applications
E- Mobility: Advantages of Castings
Flexibility
Integration
Design Freedom
Economic Efficiency
Material Characteristics
Part Characteristics
…
E-Mobility – New Applications
Overview 2014 | 03/2014 | GF Automotive67
Wheel carrier with
integrated planetary gear
Formula Student
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking68
E-Mobility – New Applications
Battery Housings
VW E-Golf
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking69
E-Mobility – New Applications
Single-Piston
Powertrain Applications
Audi A1 e-Tron Prototype
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking70
GF Automotive
Lightweigthing – Industrial Applications
Converter Housing
Drum Support
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking71
Lightweigthing – Conclusion
Proved solution for lightweigthing? Castings offer…
Broad choice of materials
High design freedom
Large potential for weight savings
High functional integration
Compared to carbon fiber much lower costs and better recyclability
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking72
GF Automotive
… for your
Lighter Future
Passion …
ContactKlaus DeckingHead of Marketing, Communication & ServicesBusiness Development New MarketsPhone +41 52 631 21 17Mobile +41 79 633 11 37Fax +41 52 631 28 [email protected]
GF AutomotiveGeorg Fischer Automotive AGAmsler-Laffon-Strasse 98201 SchaffhausenSwitzerlandwww.gfau.com
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking73
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking74
GF Automotive
Disclaimer
This document is for presentation
purposes only and should not be
construed as an offer, invitation or
solicitation to subscribe for, purchase
or sell any investment. Neither it nor
anything it contains shall form the
basis of any contract whatsoever.
Opinions expressed herein reflect the
current judgement of the management
of Georg Fischer. The presentation
contains forward-looking statements
that involve risks and uncertainties. The
actual results of Georg Fischer may
differ materially from those anticipated
in these forward-looking statements
and forecasts as a result of a number
of factors.
The management of Georg Fischer
does not accept any liability whatsoever
with respect to the use of this
presentation.
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking76
GF Automotive
Lightweighting
Bionic Design
- 32%
Material
Function Integration
- 45%
- 45%
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking77
GF Automotive
Product Segment – Passenger Cars
Powertrain
Chassis
Body / Structure
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking78
GF Automotive
Product Segment – Comm. Vehicles
Powertrain
Chassis
Frame / Cab
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking79
GF Automotive
Product Segment – Industrial Application
Energy & Engine
Industry &
Consumer
Offroad
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking80
GF Lightweight Solutions
Rohstoff- und Energieversorgung
Beschaffung und Sicherung von
Rohstoffen und Energie
Rohstoff- und Energierückgewinnung
mit Hilfe moderner Techniken
Einkauf über weltweit agierende
Spezialistenteams
Mehrjahresverträge mit strategischen
Partnern
Virtuelle Beteiligungen bei
Rohstoff- und Energielieferanten
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
Vergleich von Aluminium und Magnesium
Aluminium Magnesium
Dichte 2,7 g/cm3 1,8 g/cm3
E-Modul 70 GPa 45 GPa
Wärmeleitfähigkeit 238 W/mK 156 W/mK
Wärmeausdehnungskoeffizient 23,5 10-6/K 26,0 10-6/K
Gießbarkeit + ++
Gießtemperatur 710 – 740 °C 670 - 690°C
Wandstärken > 2,0 mm > 1,5 mm
Schutzgas (Brandgefahr) nicht notwendig SO2, (SF6)
Werkzeugstandzeit 100.000 150.000
(Kontakt)-Korrosion + -
Fügetechnologie ++ o
Recyclingfähigkeit ++ +
81
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking Magnesium-Druckguss im Motorenbau 8202/2011
Weitere Merkmale Magnesium / Aluminium
Aluminium Magnesium
Wandstärken > 3,5 > 2,5
Festigkeit + 0
Gießbarkeit + ++
Werkzeugstandzeit 0 ++
Korrosion + -
Kosten + 0
Gewinde + +
Nieten + +
Stanznieten + -
Stanzen + +
Schweissen + -
82
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
Produkteigenschaften:Magnesium im Vergleich zu Aluminium
Bessere Fliessfähigkeit
dünnwandigere Bauteile möglich (<1,5mm)
geringere Auszugsschrägen möglich
komplexere Bauteile möglich
hohe Oberflächengüte erreichbar
Geringere Toleranzen im Gusszustand erreichbar
Tlws. geringere Nacharbeit notwendig
Tlws. geringere Bearbeitung notwendig, da fertiggegossen
Mg-Legierungen haben starke Neigung zu Kontaktkorossion
Tlws. ist zusätzliche Beschichtung erforderlich
Ggfs. spezielle Fügetechnik erforderlich
83
GF Automotive
Development Competence
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking84
State-of-the-art processes:From design phase to serial
production
Virtual Development:The complete component
development from material
selection to casting
process is simulated,
validated and continuously
improved
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking85
GF Automotive
Innovation in Material, Design & Process
Process: Core Technology
Design: e.g. Cross Member Design: e.g. Structural Parts
Material: e.g. AluSiDur
High Strength Aluminum Lightweight Crankshafts
Substitution Lightmetal
Principals:
Resources in Nature are limited
Biological mass must be applied
efficiently
Structures in nature aim to
maximal light weight construction
with minimum stress loads
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking86
GF Automotive
Bionic Design
After
SiboDur® 700
6,3 kg
Before
GJS 700
7,2 kg
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking87
GF Automotive
Bionic Design Examples
- 12,5%
TopologieoptimierungTopologie
Optimierung
Bionic Design
Start Model
Finite
Element
Analyse
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking88
GF Automotive
Bionic Design Examples
Befor
GJS 400
4,4 kg
After
SiboDur® 700
3,0 kg
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking89
GF Automotive
Bionic Design Examples
- 32%
90
GF Automotive
Bionic Design
Weight reduction
Differential housing in iron
casting up to 15% less
weight than predecessor
through bionic design
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
91
GF Automotive
Substitution of System Parts
Weight reduction
Crossmember, completely
casted in iron has 17% less
weight than combined
assembly out of steel sheet
and iron
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
Source: VW
92
GF Automotive
Emission during Production Process counts
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking
Change of Perspective
GF Automotive
Development Competence
Lightweight Activities at Georg Fischer | 10/2014 | K. Decking93
State-of-the-art processes:
From design phase to serial
production
Virtual Development:
The complete
component development
from material selection
to casting process is
simulated, validated and
continuously improved