An effective addition to aluminum and engineering...
Transcript of An effective addition to aluminum and engineering...
MnE21® manganese sheet: An effective addition to aluminum and engineering plastics
- new materials require new processes
Dr. Stephen Rudzewski
Head of Technics Germany Semcon Holding GmbH & Co. KG
24. April 2012
Index
MnE21 - New materials require new processes
1
2
Intro: Light weight design betwixt ecology and cost
Important characteristics of MnE213
Examples of real MnE21 parts 4
2 Dr. Stephen Rudzewski,
Um dieses Ziel zu erreichen muss man:
Ø ganzheitlich denken
Ø querdenken
Ø oder auch einfach ganz anders anfangen …
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Introduction … Light weight design betwixt ecology and cost
Ökologie bedeutet u.a.:
Den notwendigen Rohstoff- und Energieeinsatz so intelligent miteinander zu verknüpfen, dass maximale Ressourcenschonung möglich wird.
Introduction … Sea water desalination as a source for light weight structural components
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Heat & sun
Energy
Sea water
Sea water desalination
Drinking water
Basic
factor
Natrium
Chlor
Kalium
Calzium
Magnesium
Schwefel
Fluor
Indium
Lithium . . .
Salt Industry
Fertiliser-
Food-
Elektronic-
Metal- . . .
Source of picture: www.fotolia.de
Introduction … Sea water desalination as a source of immense raw materials
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Salt
17 Mio t/year
Sea water
500 Mio t/year
• 9700000t Chlor
• 5400000t Natrium
• 645000t Magnesium
• 425500t Schwefel
• 206000t Calzium
• 199500t Kalium
• 650t Fluor
• 90t Lithium
• 60t Rubidium
• 10t Indium
• 1,6t Uran
. . .
But!!
What is a construction
material without
effective processes to
manufacture products?
It‘s only a substance!
Example Israel: Predicted demand for drinking water in 2020 approx. 2670 Mio m3/year Thereof estimated 500 Mio m3 from sea water desalination
Source of picture: www.fotolia.de
Index
MnE21 - New materials require new processes
1
2
Intro: Light weight design betwixt ecology and cost
Important characteristics of MnE213
Examples of real MnE21 parts 4
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Raw material
MnE21 - New materials require new processes …. Actual metal sheet production chain: Example engine hood
Pit
Metal-slab
Roller mill
Metal blank Metal-slab
-90%
slice
Furnace
Production plant
Press tool Metal blank
Inner structure
Assembly
gluing, riveting,
spot welding,
laser welding
etc.
Classical
aluminium or
steel hood
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Sou
rce
of
pic
ture
: In
tern
et;
Sto
lfig
®
Pit
Raw material
MnE21-Pellets
MnE21 - New materials require new processes … Overview of the „ideal“ MnE21 process
Furnace
Production plant
Stud
Inner structure
Stud casting
Extruder
Press tool Metal blank
Assembly
gluing, riveting,
spot welding,
laser welding etc.
Slice
30%
-10%
70%
Aluminium-
MnE21
composite hood
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Sou
rce
of
pic
ture
: In
tern
et;
Sto
lfig
®
MnE21 - New materials require new processes … Inline metal sheet production with the “Stolfig” extruder
● Metal sheets up to 1,8m width
● Continuous tailored blanks
● Heat of extruder directly used for
forming process
● MnE21 properties directly
adjustable by extruder
parameters
● Complete sheet production unit
fits in the space of a classical
“coil-unit” (~18m)
Benefit
No expensive roller mills anymore
Grading device
Tube opening
Extruder head
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Source of picture: Internet; Stolfig®
Druckguss
MnE21 - New materials require new processes … almost any kind of semi finished part producible
● Metal sheet, cross-section, cast
and wire producible in house
● Even complex designs can be
realised cost and weight optimal
● Welding process with same
material filler wire is a big benefit
for corrosion and strength
● Mono-material parts possible Benefit
Filler wire 1 to >5mm
Any profiles
stepless sheet thickness
MnE21 casting
Perfect eco-friendly
recycling
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Source of picture: Internet; Stolfig®
MnE21 - New materials require new processes … warm manufacturing with „inline“ metal sheet production
● Stamping forces only ~20 %
● Only small presses
● Lightweight, cheap tools
● Only few pressing stages,
example 6 instead 16
● Optimal contour accuracy
● Almost no stamping flanges
necessary
● No lubricant
● No free punches necessary
● Tool cleaning with citric acid or
vinegar
Benefit
- 70%
CO₂
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Source of picture: Internet; Stolfig®
MnE21 - New materials require new processes … assembling and subsequent processing
Benefit
● No aging or time dependend
material properties
● Suitable for cataphoretic coating
● Material mix e.g Steel/MnE21
possible
● Assembly with „all“ known
mechanical processes
● Tempered welding with all
processes
● Robust glueing process
„without“ pre-processing
● Parts cleaning with vinegar or
citric acid
Punch riveting
Clinching
Riveting Stud welding
Rivet nut Spot welding
Bonding
TIG (8l/min Ar)
Complex welding parts Laser welding up to
20m/min) Weld joints between MnE21
and zink-plated steel
Material mix Al – MnE21
Stahl – MnE21 No free punches Cataphoretic coating
Geometrically perfect manufacturing“over“
compensates lower stiffness
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Source of picture: Internet; Stolfig®
Assembly
MnE21 - New materials require new processes … only the sum of innovations makes the jump
gluing, riveting,
spot welding,
laser welding,
TIG welding etc. T
Tool
150°C-350°C
Extruder
Stud press
Furnace
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Source of picture: Internet; Stolfig®
Index
MnE21 - New materials require new processes
1
2
Intro: Light weight design betwixt ecology and cost
Important characteristics of MnE213
Examples of real MnE21 parts 4
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Important characteristics of MnE21 … a good compromise of weight and strenght
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Youngs modulus (GPa) 45 (Al~74) Density (g/cm³) 1,74 (Al~2,70) Melting temperature (°C) 650 (Al 660) Strenght (MPa) RP0,2=110-(>200); Rm=150-(>400) at >15% plastic strain
Isotropic in the linear elastic area, but anisotropic behavior in the plasticity area.
Has be taken into account to achieve feasible designs!
Important characteristics of MnE21 … the classical prejudices
Fire hazard
Up to 550°C
in ambient
air! NO! Because
no Mg-Al
eutectic
Heavy
corrosion
NO! If no Fe-
impurity
AZ31 MnE21
240h
Salt test
480h !
Salt test
1
!!!
st SSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS
Expensive NO! If
appropriate
process
MnE21-engine hood
structure can be same
price as steel structure
Bad CO²
rating
NO! If
appropriate
process
10t CO²/t MnE21
achievable
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Source of picture: Stolfig®
Important characteristics of MnE21 … a promising cost structure and good eco-friendlyness
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Cost (€) per kg MnE21 as raw material ~5,- € Cost per part compared to Aluminium Faktor 2 – Faktor 0,5 CO² / t with state of the art Pidgeon process < 20 tons (PE-International)
Today
Cost (€) per kg MnE21 as raw material < 2,- € CO² / t with latest furnace process < 10 tons
2020
Index
MnE21 - New materials require new processes
1
2
Intro: Light weight design betwixt ecology and cost
Important characteristics of MnE213
Examples of real MnE21 parts 4
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Examples of real MnE21 parts … the „ideal“ MnE21 process chain is well-proven with many sample parts
Roof cross beam: 0,52kg (1,14kg)
Door crash beam: 0,8kg (1,86kg)
IP-beam: 2,8 kg (7,2kg)
Filler wire
Engine hood structure: 2,5 kg (5,58kg)
Trunk lid inner: 1,53 kg (3,84 kg)
Seat pan: 300g (997g)
Section of door inner part
Seat pan: 305g (> 1200g)
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Source of picture: Stolfig®
Tongji Uni-Shanghai
Forschungsfahrzeug Bj. 2007
Antrieb: Brennstoffzelle
Stolfig-Rahmen MnE21
Rahmengesamtgewicht: 27 kg
(Stahl: 100 kg)
Examples of real MnE21 parts … E-mobility can be the ideal use case for MnE21
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Source of picture: Stolfig®
Examples of real MnE21 parts … many parts are already realized in a show car
Roof
rear cross
beam
0,4 kg
Roof
middle cross
beam
0,46 kg
trunk lid hinge
modul
le+ri
each 0,37 kg
Roof
front cross
beam
0,52 kg
IP-Beam
ZSB
2,6 kg
Hood hinge
Modul
le+ri
each 0,2 kg
Rear door
crash beam
le+ri
each 0,6 kg
Front door
crash beam
le+ri
each 0,8 kg
Fender braket
le+ri
each 0,14 kg
rear panel
top edge modul
2,67 kg
Back rest
5,22 kg
Rear doorFront doorFender braket
Front door
beam
0,46 k
beam
0,52 kg kg
0,46 k52525252525252525252525252525252525252525252525252525252525252525252525252525252525252 kg 0,4 kg kg 464646464646464646464646464646464646464646464646464646464646464646464646 k k k k k k k k k k k k k kg4 kgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkg ch 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0,37
Rear bumper
beam
1,99 kg
Trunk lid
inner structure
modul
1,53 kg
7 kg7 kg
inne
Weight saving:
> 36 kg
Fire wall
mounting plate
1,36 kg
Engine hood
inner structure
modul
2,5 kg
Front bumper
beam
1,78 kg
Front door
top edge
reinforcement
le+ri
each 0,61 kg
Front door
top edge
reinforcement
le+ri
each 0,32 kg
Reinforcement
mounting block
le+ri
each 0,08 kg
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Source of picture: Internet
Semcon going next steps in structural MnE21 parts … an innovative B-post concept as a laboratory for manufacturing technology
Concept background and
targets
● Substitute for steel post in Al-space frame
● „Mono block assembly“ of
all parts by laser welding
● High quality, low tolerance laser welds by use of “hot
plasticity effect”
● Low tolerances through warm and tempered assembly
● Inner reinforcement in hot (~400 C) impact extrusion technique > „bionic“
shaping
● And some more ideas… Picture: Frankfurt Motor Show Semcon Booth 16.9.2011
First handmade show part < 8 weeks
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Source of picture: Semcon
Summary: … Magnesia/MnE21 will become a new branch in the light weight arena again
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Aluminium / plastic
Steel / plastic
Aluminium / steel body
BWM 5er
AC C Karosserie
unibody
steel spaceframe
composite construction
Fiat Multipla
CFRP-Monocoque
hybrid body
plastic body
steel body
aluminium body
aluminium spaceframe chassis
aluminium spaceframe hybrid construction
unibody construction
Lotus Elise
Audi
A2
Jaguar XJ
Magnesia/MnE21 Structure - the new branch
Source of picture: Internet, Semcon
Summary: … Magnesia/MnE21 will become a new branch in the light weight arena again
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It is not the question IF magnesia/MnE21 will be used in large-area structural parts
but
only WHEN!
Contact
Dr. Stephen Rudzewski Technikleiter Deutschland
Semcon Holding GmbH & Co. KG Neuhartshöfe 3 85080 Gaimersheim
Telefon +49 (8458) 3289 709 Mobil +49 (172) 3781 568 [email protected] www.semcon.com
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