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Simply light! – New ways for the realization offuture technologies and business models for
innovative lightweight concepts in automotive engineering*Online Meeting - "Sum of the Parts: Light Weight Materials in Automobiles"
AGRION Internet Conference, January,19th, 2011Dr.- Ing. Peter Klose, MBtech Consulting GmbH, Sindelfingen
* 10th International Symposium Stuttgart Automobile- und Engine technologyHaus der Wirtschaft, March 17th, 2010 (Excerp)
2006-XX-XX 22
MBtech provides engineering and consulting services for the automotive industry worldwide
2
2700 employees worldwide
Turnover: € 320 million in 2010
GLOBAL PRESENCE
POSITIONING
Close relationship to customers on three continents
FACTS & FIGURESDie MBtech Group
The MBtech Group is a leading global provider for automotive engineering and consulting services
MBtech offers comprehensive expertise along the entire automotive product value creation process and product life cycle
MBtech is a business group within the Daimler AG
High level of customer and service orientation- Interdisciplinary project teams- Close partnership with suppliers, customers and
cooperation partners- Outstandingly competent, professional and
committed employees
1 MBtech Group overview
10. Internationales Stuttgarter Symposium Automobil- und Motorentechnik
2006-XX-XX 33
MBtech services cover the entire range of automotive engineering and consulting services
Class A and technical styling
Body developmentBody-in-whiteExteriorInterior
Chassis development
Full vehicle integrationDesignNumeric calculationSimulation
Full vehicle testing and validation
Production Engineering
Methods, training, support
Combining design, functionality and economy
Management Consulting
Technology & Innovation Consulting
Process Consulting
Program & Project Consulting
Business Academy
Technology and process expertise for long-term success Motor concepts
Engine variants
Exhaust gas after-treatment
Turbocharging systems
Combustion process development
Development of injection systems
Development and operating test fields
In-vehicle powertraintesting
Planning and design of production facilities and processes
Innovative solutions for the entire powertrain
Systems engineering
Software engineering
Test Engineering
Validation & compliance
EMC Services
Reliable, high-performance customized E/E solutions
consulting vehicle engineering powertrain solutions electronics solutions
3
1 MBtech Group overview
10. Internationales Stuttgarter Symposium Automobil- und Motorentechnik
DVM day 2008Dr. P. Klose, MBtech Consulting 4
Light-weight design is more than the use of light materials
Light-weight function
Acoustics, smart structuresVibration abs.WarmthCorrosion/ TribologyMechatronics, E/ET
Light-weight materialsHigh-strength steelsLight metals Al, Mg, TiSMC, composites (GF/CFK)Micro-disperse, nano-materialsFunctional paints/coatingsHybrid composites (Metal/plastic)Anisotropic materials (positioned
solidified)
Light-weight constructionLaser welding, laser solderingTailored BlanksRoller profilesMAG welding
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24
3
Light-weight molding
Red. mounting offsetOpt. mountingNode conceptsCasting proceduresHollow structuresHydroforming
Light-weight design concept
Broader application spectrumsType-independent reinforcementDigital material development and validationModularization
The optimal light-weight design potentials can only be realized through an integrated approach
Efficient material systems, processing
Innovative joining technologies
Reducing complexity
Function integration
Modular construction
Flexible manufacturing concepts
Influencing factors
Source: MBC, Dr. Klose 2008
2 Light-weight design concepts, Trends (Overview)
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Innovations in the automotive industry are becoming more com-plex and need to be addressed increasingly cross-functionalNetworked Innovation Fields : fast processes, lightweight structures, efficient drives
Fast processesLightweight structuresEfficient drives
Innovation topics "Energy-efficient vehicle" (selection)
Source: MBtech Group
Fast implementation
Consistent linking physical-digitaltoolsRapid-technologies ready for serailproductionConsistent, linked simulation tools
Lightweight design
Intelligent, multi-functionalStructures
Hybrid Material SystemsEconomic production processes
Propulsion technology Drive technology - Optimization Combustion- Optimization mechanical losses- Electric Cars / HybridInfrastructure technology
10. Internationales Stuttgarter Symposium Automobil- und Motorentechnik
3 Trends in technology
666
New materials – point of departure for each automotive lightweight design applicationThe potential use of materials available is determined by their functions(e.g. crash, lightweight design), recyclability, costs, surface quality, joining technology and theavailability of simulation data (static/ dynamic)Steel [1] Aluminium [2] Magnesium [3]
Steel-Al hybrid [2] Plastic-Al hybrid [2] Plastics/composites [4]
Source: [1] Opel GmbH [2] Audi AG [3] Volkswagen AG [4] Daimler AG 10. Internationales Stuttgarter Symposium Automobil- und Motorentechnik
3 Trends in technology
7
2010 ?
Use of tailored blanks in volume series
Thin-gauge high-strength blanks
1982
CitroenTraction Avant
1934
Large presses for body panels
Lancia Lambda
1923
100% galvanizedsteel car body
1975
First assembly line produced Ford Model T
1910
Pressed steel frame(Mercedes)
1902
ULSA-x and NSB studies
Milestones of steel car body technology – “design“ competition between material development and process technology
Source: By TKS 2006
1986
1994 - today
3 Trends in technology
DVM day 2008Dr. P. Klose, MBtech Consulting 8
TrendsDiverse application spectrum of modern steels
Tensile strength Rm [ N/mm² ]
0
Stra
in a
t fai
lure
A80
[ % ]
Al alloy
Mg alloy
1200200
40
20
0 400 600 800 1000 1400
60
Stainless steels
Advanced Steels
X-IP
Higher expansion with increased stability
Expanded product application spectrum in the body and chassis areas
Increased crash-safety through the work-hardening effect
Personal security, ballistic protection
Broader range of operating temperatures
Easy processing
Proven surface protection
Established joining procedures
Thin metal structures
Use of new tool technologies, materials, resources, cutting materials
Develop cooled forming tools with controlled blank holders
TemperatureSurface/interfaces
New material concepts offer a unique range of applications and cost/benefit ratiosOverview: High-strength steel alloy systems /alternative material groups
Conventionalsteels
Source: MBCauf basis TKS data Material symposium Vehicle technology, Stuttgart 2007
CeramicsTitanium
3 Light-weight design concepts, Trends (Overview)
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The choice of lightweight-appropriate joining technologies/hybrid technologies has to be matched to the material systems (excerpt)
Joining costs/ complexity
Joiningquality
MiG brazing
Resistance spot welding
Clinching
CMT
US-friction-welding Al+ST
Self Piercing Rivets
Bonding + boltsLaser welding
Friction steer-welding
Flowdrill
Hybrid Joining
Bonding/NT-diffusion brazing
Low High
Low/No
adhesivebond
High/Full
adhesivebond
Meeting Akzo Elring Greiz 101018, Dr. Klose MBtech
3 Trends in technology
10
New innovative surface protection processes will revolutionize conventional pre-treatment and paint technology
Al
Zn Mg
Impr
oved
corro
sion/w
hite r
ust
resis
tance
Hybrid
desig
n with
stee
l/ Al
Improved white rust resistancePassivation of zinc layers
(Mg-compatible coatings on steel)
White rust resistance (Mg-
compatible coatings on steel)
Deposition of pure metals duringthe gaseous phase – Al, Al/Mg, Zn, B, Fe– as pure metal or– graded layers – at normal pressure
Application of combined process technologies– E.g. galvanizing– Diffusion processes– Heat treatment processes
Unaffected by the part geometry/contourEasy integration (regardless of direction – horizontal/ vertical)Easy loading/unloadingCan be combined with variousafter treatmentsFree of Cr and Cr-VI
Benefits
Technology of the MO CVD process(Metallorganic Chemical VapourDeposition)
Standard parts
SheetsExhaust manifold
Source: InnCoa GmbH 2008
Business case- Innovative coating system
1111
Lightweight by function integration: micor-disperse isolation in the chassis saves weight, constructed space and costs
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Initial situation
Chassis (tailored blank) 18,5 kgAcoustics insulation (heavy mats) 3,5 kgHeat insulation (shielding plates) 1,3 kg
Integrated acoustics and heat insulation
Double walled transmission tunnel with micro-disperse layerDrop of acoustics insulation and shielding platesShortening of assembly processWeight reduction -1.3 kgIncrease of rigidity through sandwich construction
Isolation of chassis – Series stand BR212 Function integrated chassis in sandwich construction (concept draft)
Sandwich concept offers a weight reduction of 4.8 kg with lowered costs and drop of 10 parts
10. Internationales Stuttgarter Symposium Automobil- und Motorentechnik
Business case- Innovative heat insulation system
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The timely change of the maturity degree of different technologies will determine the future body in white design
Application
Pilot application
Pilot manufacturing
Demonstrators
Feasibility studies
Material characterizationBasics
Maturity degree
Research Development Production
AdvancedMg-alloys
Ti-alloys
Highly firm structure-CFK
StandardMg-alloys
Optimized steel lightweight
Nano-mat., new surface technologies
Smart structures
TiAl
Metal- and ceramic-sponges
Metal matrix composites
Ceramic application(e.g. engine components,
surface technologies)
Al-alloys
Meeting Akzo Elring Greiz 101018, Dr. Klose MBtech
3 Trends in technology
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The realization of innovative vehicle concepts requires a parallel development of agile and flexible organization formsBusiness case: platform configuration of OEM with respective complexity mgmt.
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Parallel organization development forthe realization of new vehicle constructions
Material– Aluminum– Steel– Plastic– Hybrid– …
System– Shell construction– Integral carrier of transmission– Structure carrier of transmission– Quantity– …
Geometry conditions– Product– Tool design– Production form– Production technology– Inclusion and clamping concept– …
Processes– Added value– Material flow– Capacity– Flexibility– Suppliers– …
Product requirements– Design– Performance specifications– Law requirements– Available space– Force progression curve– …
4 Towards realization of innovative lightweight concepts
Joining technologies– Welding– Riveting– Adherence– Clinching– …
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Lightweight in vehicle development – the entrepreneurial dimension
Styling
Processvalidation
Al PVDZn CVD
Material/surface
Concept Construction
Modules
Test loops
SimulationTechnology/electric/
electronic
PrototypesDigital plantEquipmentProduction Tools
5 Outlook
Lightweight in the car is not only a question of the material or the construction way. If lightweight has to be carried out effectively and efficiently the whole product development process has to be aligned with it – a management of competences together with system partners is necessary
10. Internationales Stuttgarter Symposium Automobil- und Motorentechnik