50 Year Perspective of Automotive 50 Year Perspective of Automotive Engineering Body Materials and...

7/31/2019 50 Year Perspective of Automotive 50 Year Perspective of Automotive Engineering Body Materials and an Engineering Body Materials and an Analysis of the Future Analysis of

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50 year Perspective of Automotive50 year Perspective of Automotive

Engineering Body Materials and anEngineering Body Materials and an

Analysis of the FutureAnalysis of the Future

Jody N. HallJody N. Hall

Manager, Global Die Standards & Materials ApplicationsManager, Global Die Standards & Materials Applications

General Motors Manufacturing EngineeringGeneral Motors Manufacturing Engineering

Great Designs in Steel 2008Great Designs in Steel 2008


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Steel Becomes theSteel Becomes the Material of ChoiceMaterial of Choice

for Auto Bodiesfor Auto Bodies

Original bodies made of wood& steel

Quick to tool, easy to change

Large number of skilled

workers

1914 Dodge & Budd produce5,000 all-steel bodies

All-steel body was lighter,stronger, easier to make

Most significant advantage wasin painting

Benz Patent Motorwagen 1886 (Replica)

Dodge Brothers Touring Car 1917
http://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/4/40/1917_Dodge_Touring_Car.jpghttp://upload.wikimedia.org/wikipedia/commons/4/40/1917_Dodge_Touring_Car.jpghttp://upload.wikimedia.org/wikipedia/commons/4/40/1917_Dodge_Touring_Car.jpghttp://upload.wikimedia.org/wikipedia/commons/4/40/1917_Dodge_Touring_Car.jpghttp://upload.wikimedia.org/wikipedia/commons/4/40/1917_Dodge_Touring_Car.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpg


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Every time the price ofEvery time the price ofsteelsteel goes up,goes up,DetroitDetroits auto makers moan in anguishs auto makers moan in anguish

and intensify their search forand intensify their search for

replacementsreplacements


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Every time the price ofEvery time the price ofsteelsteel goes up,goes up,DetroitDetroits auto makers moan in anguishs auto makers moan in anguish

and intensify their search forand intensify their search for

replacementsreplacements

gasgas


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Materials Causing the Biggest Stir in BodyMaterials Causing the Biggest Stir in Body

TechnologyTechnology

PlasticsPlastics--been getting the big playbeen getting the big play

as successor to steelas successor to steel

Aluminum AlloysAluminum Alloys--about as strong as steel,about as strong as steel,

less than half the weightless than half the weight--usedused since birth of autosince birth of auto

--most plentiful metal on earthmost plentiful metal on earth

Magnesium AlloysMagnesium Alloys

--even lighter than aluminum,even lighter than aluminum,stronger for its weight than steelstronger for its weight than steel

--most easily machined and castmost easily machined and cast

--enough in the oceanenough in the oceanto provide 100,000,000 tons a yearto provide 100,000,000 tons a year


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Published October 1953

The day of the passengercarmade primarily of ironand steelis on the wane!Some sources predict that

by 1960a Cadillac will weighless than a 1953 Chevroletand a Chevy will probablyweigh about as much as amotorcycle.


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Prediction 50+ Years AgoPrediction 50+ Years Ago

SteelAl Plastics

Mg

FUTURE

PAST


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Steel Mass ReductionSteel Mass Reduction

Time

M

assReduc

tion

Opportunity

0%

20%

10%

30%

40%

50%

1970 1990 2000 2010 20201980 2030

MILD STEELS

CONV HSS


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54.6%

12.7%

15.8%

0.8%9.5%

6.6%

Current Body and Closure Metallic MaterialCurrent Body and Closure Metallic MaterialContent by Type for North AmericaContent by Type for North America

Mild SteelMild Steel

MediumMedium

HSSHSS

850 Pounds850 Pounds

AdvancedAdvanced

HSSHSS

BakeBake

HardenableHardenable

SteelSteel

ConventionalConventional

HSSHSS

Aluminum &Aluminum &

MagnesiumMagnesium

Source: Ducker WorldwideSource: Ducker Worldwide

20072007


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The Question isThe Question is

Why do these materials continue to fall

short of the prediction?


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Comparison of Materials by PerformanceComparison of Materials by Performance

Density Modulus Tensile

Strength

Elongation Corrosion

Resistance

Mild Steel

Aluminum ++ -- 00 00 0 /0 / ++

Magnesium ++ -- -- 00 -- 0 /0 / --

Polymers &Composites ++ 0 /0 / -- --/ 0 // 0 / ++ -- ++

- - - - - - - - - - BASELINE - - - - - - - - - -

KEY: 00 = equal ++ = better -- = worse


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Comparison of Materials byComparison of Materials by

Other Important CharacteristicsOther Important Characteristics

CostCost

(Est. $/lb.)(Est. $/lb.)

AvailabilityAvailability(Annual Metric Ton(Annual Metric Ton

Production)Production)

EnvironmentEnvironment(Primary Production Emissions(Primary Production Emissions

reported by industry)reported by industry)


(Baseline)(Baseline)$0.50$0.50 110 Million110 Million easy to recycleeasy to recycle

Emissions = 2.3Emissions = 2.3 2.7 kg CO2.7 kg CO22/kg/kg

AluminumAluminum

(Al)(Al)

$1.00$1.00 2.5 Million2.5 Million easy to recycleeasy to recycle

Emissions = 13.9Emissions = 13.9 15.5 kg15.5 kg

COCO22/kg/kg

MagnesiumMagnesium

(Mg)(Mg)



COCO22/kg/kg

PMCPMC $1.20$1.20 --

6.506.50UnknownUnknown difficult to recycledifficult to recycle



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6.6%

9.5% 0.8%

15.8%

12.7%

54.6%

Current Body and Closure Metallic MaterialCurrent Body and Closure Metallic Material

Content by Type for North AmericaContent by Type for North America

Mild SteelMedium

HSS

850 Pounds850 Pounds

AdvancedHSS

BakeHardenable

Steel

Conventional

HSS

Aluminum &Magnesium

Source: Ducker Worldwide

2007


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Comparison of Materials by PerformanceComparison of Materials by Performance

Density Modulus Tensile

Strength

Elongation Corrosion

Resistance

Mild Steel

Aluminum ++ -- 00 00 0 /0 / ++

Magnesium ++ -- -- 00 -- 0 /0 / --

Polymers &

Composites

++ 0 /0 / -- --/ 0 // 0 / ++ -- ++

HSS/AHSS 00 00 + ++ + 0 /0 / -- 00

- - - - - - - - - - BASELINE - - - - - - - - - -


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Comparison of Materials by ManufacturabilityComparison of Materials by Manufacturability

Steel &Steel &

HSS/AHSSHSS/AHSS

AdvantagesAdvantages::

FormabilityFormability

WeldabilityWeldability

InfrastructureInfrastructure

Painted SurfacePainted Surface

DisadvantagesDisadvantages::

CastabilityCastability

AluminumAluminum


FormabilityFormability


Painted SurfacePainted Surface


LowerLowerformability thanformability than

steelsteel


MagnesiumMagnesium




FormabilityFormability ElevatedElevated

temperaturetemperature

stamping &stamping &

hemminghemming


Polymer/Polymer/

CompositesComposites


Low costLow cost

toolingtooling

Shorter leadShorter lead

timetime


Cycle TimeCycle Time InfrastructureInfrastructure

Difficult toDifficult to

repairrepair

PaintedPainted

SurfaceSurface


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Comparison of Materials byComparison of Materials by

Other Important CharacteristicsOther Important Characteristics

CostCost

(Est. $/lb.)(Est. $/lb.)

AvailabilityAvailability(Annual Metric Ton(Annual Metric Ton

Production)Production)

EnvironmentEnvironment(Primary Production Emissions(Primary Production Emissions

reported by industry)reported by industry)


(Baseline)(Baseline)$0.50$0.50 110 Million110 Million easy to recycleeasy to recycle


AluminumAluminum(Al)(Al)



COCO22/kg/kg

MagnesiumMagnesium

(Mg)(Mg)



COCO22/kg/kg

PMCPMC $1.20$1.20 --6.506.50

UnknownUnknown difficult to recycledifficult to recycle Emissions = 2.5Emissions = 2.5 23.0 kg CO23.0 kg CO22/kg/kg

HSS/AHSSHSS/AHSS $0.55$0.55 Included in MildIncluded in Mild

SteelSteel

easy to recycleeasy to recycle



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Engineering StrategyEngineering Strategy

MaterialsMaterials

ManufacturingManufacturing

DesignDesign


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Global MarketGlobal Market

North America

Well developed market

Consumer demand for largevehicles

Relatively low fuel prices

Primary challenges U.S. CAFEand emissions regulations(particularly diesel); strictcollision performancerequirements

Latin America, Africa & Middle East

Diverse market

New market players

Lead in alternative fuels,particularly ethanol

Primary challenge is productcost

Opportunity for more growth

Europe

Well developed market

Consumer demand for a balance of

utility & efficiency

Relatively high fuel prices

Taxes on poor fuel economy &emissions

Primary challenges CO2 commitmentand Euro 5 emissions; strict collisionperformance requirements

Asia Pacific

Fast growing diverse market

Infrastructure still developing

Primary challenges are new fueleconomy/emission regulations


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Conclusions

Always be a need/desire to push tolightweight materials for the auto industry

Doesnt mean no steel

Current prediction is mainly some form ofsteel

Best value to customer (performance/cost)

However, disruptive event(s) is as likely, or

even more likely, than ever before

50 Year Perspective of Automotive 50 Year Perspective of Automotive Engineering Body Materials and...

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