The essential contribution of recycling in a sustainable aluminium value chain constellium nov 2016
Constellium high strength crash management systems 20150609
-
Upload
constellium -
Category
Presentations & Public Speaking
-
view
132 -
download
2
Transcript of Constellium high strength crash management systems 20150609
High strength crash management systems
Introduction
Constellium key figures
Cross functional and integrated Constellium Innovation Process
RCAR Structure
High strength crushable alloys (C28 and above)
Towing
Correlation Simulation & Testing
Constellium Innovation
RCAR Bumper
High strength structural alloys (HSA6)
Constellium Innovation
Conclusion
AEE 2015 Nürnberg
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 2
Constellium is a leader in innovative aluminium-based
solutions
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 3
10,000 employees*
€ 4.7 billion in sales*
23 manufacturing sites
C-TEC, our world-class Technology Center
Headquartered in Amsterdam, The Netherlands.
Corporate offices in Paris, France, Zurich, Switzerland and
New York, USA
*The
com
bine
dun
audi
ted
pro
form
are
venu
ein
form
atio
nfo
rth
eye
arend
ed
Dec
embe
r31
,201
4pre
sent
edab
ove
give
sef
fect
toth
eac
quisition
of
Wise
asif
itha
doc
curred
onJa
nuary
1,20
14.
Thi
sin
form
atio
nis
pre
sente
dfo
rin
form
atio
npurp
ose
son
lyand
does
not
purp
ortto
repre
sentw
hat
Con
stel
lium
actu
alre
venu
esw
ould
have
been
had
the
acqu
isitio
noc
curred
onth
eda
tein
dica
ted,
nori
sitne
cess
arily
indi
cativ
eof
futu
rere
sults
.
Constellium is a market leader in Automotive Structural applications
Crash Management Systems• ~ 55% of sales
Side Impact Beams, other Safety Systems
• ~ 15% of sales
BIW Structural Parts• ~ 30% of sales
Main products
Automotive Structures
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 4
Define targets, (strength, crush,
corrosion resistance, etc.), alloy
design and process conditions
Undertake rapid prototyping
experiments - cast, extrude and
test a full range of potential alloys
Analyse data and select only the
few best candidates
Scale Up – Prototypes, process
optimisation & qualification testing
Technology / Knowledge transfer
to the extrusion plants
In house research centre (C-TEC) & Integrated R&D
Network
Lab scale DC caster & 5MN press
Full scale DC casting centre with MC & 6”
fully integrated extrusion press line
& ageing oven (*)
(*) Government funding secured in partnership with JLR to establish a Constellium University Technology Centre at Brunel University
36
6M
Pa
Advanced Die Design Models – Shape,
microstructure & extrudability
Re-Thinking Extrusion Alloy Design And Manufacturing Process
Alloy & Process Development
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 5
Re-thinking alloy design and manufacturing
process, permitted to combine upsides of
current 6xxx and 7xxx solutions to obtain
press-quenched high-strength 6xxx alloys
Re-thinking alloy design and manufacturing
process, permitted to combine upsides of
current 6xxx and 7xxx solutions to obtain
press-quenched high-strength 6xxx alloys
Focus on High Strength Alloys – 6xxxRe-thinking manufacturing process and alloy design
Press quench, standard billet purity
(easy to recycle), excellent corrosion
resistance, homogeneous properties
Standard billet purity (easy to recylce),
excellent corrosion resistance
Separate quench, heterogeneous
properties
Current solutions with
Rm sup. to 400MPa
Future state with
Constellium HSA – 6xxx
Press quench if no formability
requirements, homogeneous
properties
High billet purity, Stress-corrosion
cracking risk, formability guaranteed
only with separate quench
6xxx alloys (e.g. AA 6056)
7xxx alloys (e.g. AA 7108A)
+
+
-
-
+
-
Constellium HSA – 6xxx
Automotive Engineering Expo 2015 Nürnberg 9th - 10th June 6
High Strength 6xxx Versus High Strength 7xxx
Extrudability/Strength Compromise
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 7
50
60
70
80
90
100
110
300
320
340
360
380
400
420
440
EX
TR
UD
AB
ILIT
Y (
%)
RM
(M
PA
)
Strength potential Rm (MPa) Relative extrudability
Low Speed Insurance Test
9th - 10th June 8
RCAR Structure Test
Objective of Test
• Rigid barrier in steel
• Overlap 40% of the vehicle width w/o exterior mirrors
• Impact velocity VF = 15,0 km/h ( +1/-0 km/h )
• At the moment of impact the vehicle shall be free of the propulsion system
• Test vehicle weight = curb weight with full fuel tank + additional test devices and 75 kg ballast for the driver
Objective of Development
• System with maximum efficiency of energy absorption
• No damage of cooling system (front system)
• No damage on the longitudinals
• No side collapse during crash
Automotive Engineering Expo 2015 Nürnberg
New Alloys for light weight design
C28 crushable alloy
9th - 10th June 9
0.00
0.10
0.20
0.30
0.40
0.50
0 0.1 0.2 0.3 0.4 0.5
True strain
Tru
e st
ress
(M
Pa)
EN 6060-T62
C28
New Constellium C28 crushable alloy
YS ≥280MPa vs. 200MPa for 6060
Potential for weight savings on crush
boxes up to 20%, depending on designs.
Higher strength of Heat Affected Zone of welded assemblies
Excellent ductility
C28 solution: from a 1 fold only to a fully
crushable performance with high
resistance
C28 solution: from a 1 fold only to a fully
crushable performance with high
resistance
Microstructurally Engineered 6xxx with YS > 280MPa
Best crash index of 18 (Average: 15)
where same strength products gave an
initial best crash index of 12 (Average: 9)
Automotive Engineering Expo 2015 Nürnberg
RCAR Structure Test - Efficiency CB
Low Speed Insurance Test
9th - 10th June 10
Typicall AL System
• Fmax = 120 kN
• smax = 170mm Intrusion
• Emax,theor. = 120KN x 0,170m = 20.700J = 100%
• E System= 18.200J = 88%
Efficiency-rate = Emax = Fmax x smax
= 100%
Fmax = Defined bycustomer (Max force
of longitudinals)
smax = Defined by customer and its
package
Automotive Engineering Expo 2015 Nürnberg
Correlation FEA & Testing
Towing loadcase
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 11
Objective of test:
• No major plasticity's
• No damage of car backbone structure
• Towing cycle fulfilled
Objective of Development
• System with maximum stiffness
• No negative impact on all other loadcases
#1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11 #12 #13 #14 #15
Hardware 0,00 0,00 0,00 0,10 0,10 0,10 0,10 0,10 0,30 0,50 0,50 0,60 0,60 0,70 0,50
FEM 0,06 0,05 0,06 0,12 0,13 0,20 0,27 0,32 0,38 0,61 0,65 0,65 0,62 0,81 0,60
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
0,90
Pla
sti
c D
efo
rmati
on
[m
m]
Towing Cycles
Towing Loadcase
Correlation FEA & Testing
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 12
Benefits:much more mechanical „guidance“
Optimised deformation performance
Optimised load
sustainable
Towing Loadcase
Standard Concepts vs. Constellium Innovation
Standard towing concept:
Towing eye welded into beam
Standard towing concept:
Towing eye welded into beam
Patented Constellium innovation:
Towing eye extruded in CB
Patented Constellium innovation:
Towing eye extruded in CB
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 13
Why RCAR Bumper?
Low Speed Insurance Test
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg
Bumpers don‘t Bump ! Component Simulation with Trolly
RCAR Bumper Test
10 kph
Central Impact
Defined Barrier height
No damage on BiW Structure
14
Objective : Min.Bumper Beam Mass with optimal Beam depth
Shape Optimization
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 15
60826082
HSA6HSA6
Low Speed Insurance Test
RCAR bumper advantages mass / performance HSA6/6082
Option #1:
Potential usable for weight reduction
Intrusion-Performance:
neutral @ 100mm
Weight:
290g (= 12,4%) weight saving through
HSA6
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 16
60826082
HSA6HSA6
Low Speed Insurance Test
RCAR bumper advantages mass / performance HSA6/6082
Option #2: Potential usable for
intrusion optimisation without weight-
increase
Intrusion-Performance:
9mm Intrusion optimisation through
HSA6
Weight:
neutral
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 17
Innovation CMS-design 3D, overlap -optimisationRCAR-Bumper overlap QT / Barrier
poor constellation!
RCAR-Bumper-overlap QT / Barrier
with 3D-bended QT = optimised constellation!
Solution: 3D-bumper
RCAR bumper design optimisation 3D
Innovation for light weight design
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 18
Lightweight StrategyLightweight Potential based on similar functions
Lig
htw
eig
ht
Po
ten
tial
based
on
sim
ilar
fun
cti
on
Steel Aluminium Magnesium
CFK quasi isotropic CFK unidirectional
- 20 % - 30 % - 55 %
- 10 + x %
HSA6
Package and Parameter study
Analytical optimisation- 30 %
Automotive Engineering Expo 2015 Nürnberg
The right design, with the right material, at the right place for optimised lightweight, performance and costs!
9th - 10th June 19
Requirements, objectives, innovation strategy
CMS design
9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 20
CMS System:
• Active-CMS
• Semi Active / 100% Active Systems
Crashbox System:
• Crashbox Innovation
• Low & Highspeed
Beam System:
• Springback Beam (Pedestrian optimised 2nd Loadpath Beam)
CMS Beam
• With Integrated PedestrianProtection System (SMIF)
Pedestrian System
• Pedestrian Protection Honeycomb
Component crash & correlation
Full vehicle crash & correlation
Virtual design and simulation to be continued
Mit freundlicher Genehmigung: BMW AG