© BENTELER-Gruppe | Seite 1

BENTELER Automotive

Lightweight Applications UsingAluminum Tailored Extrusions –Sivanathan Prasoody

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Contents

1. 6xxx and 7xxx Series Alloys2. Aluminum Crash Management Systems3. Structural Solutions using Tailored Extrusions

3

7xxx: Al + Zn + Mg (+ Cu)6xxx: Al + Mg + Si (+ Cu)

Benteler Cast House

Narrow casting limits

Process control

In-house competence

High quality

0

100

200

300

400

500

600

700

800

700330 710850 710870 700362 710872 704670 704682 704692 7090

Rp0

,2 (

MP

a)

Forge S

tock

0

50

100

150

200

250

300

350

400

450

606006 606035 606385 6005A 608250 611020 608255 611050

Typi

cal R

p0,2

(MP

a)

New

! (Forge S

tock)

6xxx

6xxx and 7xxx Alloy Development

7xxx

4

Integrated Optimization – Product, Process and Materi al

+

Manufacturingvalue chain

Casting Extrusion Forming Finishing

Engineering value chain

Alloy and heat

treatment

Extrusion process

Forming process

Tooldesign

Productdesign

Prototyping and Product

verification

Pro

toty

pes

Tool

ing

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Monoblock Aluminum Crash Management System

Assembly oftowing nut

Assembly oftowing nut

Processing of 7xxx series alloy CMS

Heat-treatment

+ 7xxx Monoblock (single piece design)

+ Reformed for performance and packaging

+ Integral Flange for mounting

+ No joining of crashcans

+ Function of crashcans met by tuned cross-section Total Weight: 3,2kg

Mass reduction through part integration

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High Strength 7046 Alloy for Crash Management

+ Suitable for open profiles

+ 7046 alloy family

+ Formability similar to current 7xxx alloys

7108.50Rp0,2~ 350

MPa1.8 kg

7046.92Rp0,2~ 500

MPa1.3 kg

Schematic bumper beam with open section

Festigkeitsübersicht BAS 7xxx Legierungen

300

350

400

450

500

550

7003.30 7108.50 7108.70 7003.62 7108.72 7046.70 7046.82 7046.92

Rp0

,2 T

ypis

ch (

MP

a)

Overview strength of 7xxx alloys

27% weight reductionwith 7046 alloy

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High Ductility 7xxx for CMS

• Dynamic Effects

• Welding Effects

• Forming Effects

• Material Effects

• Temp. Effects

Design Criteria

Side rails front

Node/Joint

Sills

Pillars

Upper Crossbeams

Lower Crossbeams

Pillars

Floor

Lower Crossbeams

Doors & Closures (Inner Panel)

Doors & Closures (Reinforcements)

Firewall

Strut Front

Strut Rear

Node/Joint

Upper-front-frame

TEB & TEx Parts/Assemblies – Another Approach to BIW

Roof BowsIP Carrier

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TEx Parts – Extrusion to Part, Examples

9

Crossmember

Header

Roofbow

Brackets

TEB & TEx Parts/Assemblies– Process

TEB/TEx Process

• Extrusion• Sawing• Optional Solutionizing• Lubrication• Multi-step forming + Trimming• Optional Cleaning and Passivation• Heat Treatment

AdvantagesProven reliable ProcessIncrease in Formability of precipitation hardening Materials• Complex Forming/Parts Integration• Forming high Strength Alloys• Customize Parts Properties• Low Cost Material

DisadvantagesSerial Process requires specific Equipment and Tools• High technical effortIncreased Process- and tooling expenditure• Dedicated Feed, Correct, Cut, Pre-Heat,

Quench, Clean, Coating Processes required

Increased Tooling Expenditures for TExForming

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� Multistep press-forming

� Single piece solution

� 6xxx alloy

Front End with Tower Strut

forming process with 6 steps one-piece component

Advantages

� high integrated part

� low weight

� excellent cost-weigh-benefit

� No joining processes

Extrusion cross section

1,5mm

2,4mm

2,0mm

load-compliant

thickness

Process:

TEx Parts – Strut Tower Brace

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12

Multistep Press Forming

BMW, 5/7 seriesFrontmodule components

Tolerance adjustment betweenBIW and front module

� Multistep press-forming

� Reduced assembly

Latch Cross-Member

Weight reduction >25% versus Steel

TEx Parts – Front Cross-Member

� Vehicle: AUDI A3 (MQB)

� Material: S420MC

� Weight: 0,79Kg� Supplier: -

� Vehicle: BMW 1st Series (2012)

� Material: Steel

� Weight: 0,83Kg� Supplier: Cimos

� Vehicle : Lancia Delta 2009

� Material: Steel + PAGF

� Weight: 1,08Kg� Supplier: -

Weight: 0.4Kg

(50% lighter)

Steel Welded Shell Concepts

BENTELER Aluminum Extrusion Concept

Steel Press-part Concepts

Hybrid Concepts (Steel/Plastic)

picture only symbolically

TEx Parts - Brake Pedal

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Extrusioncross section

TEx Parts – Innovative Door Reinforcement Approach

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15

TEx Parts - Lower Control Arms

Product description

• Light weight concept and construction

• Open profile with formed edges as reinforcement

• High formability high strength aluminum alloys 6082 (T6) due to optimized process

• Scalable using variable wall thickness

Product description

• Light weight concept and construction

• Open profile with formed edges as reinforcement

• High formability high strength aluminum alloys 6082 (T6) due to optimized process

• Scalable using variable wall thickness

Customer Benefits

• Weight reduction up to 35%

• Stiffness/Buckling increase up to 50%

• No coating needed

• Complete value chain by Benteler(cast house / tool shop / production)

• Competitive cost / weight ratio

Customer Benefits

• Weight reduction up to 35%

• Stiffness/Buckling increase up to 50%

• No coating needed

• Complete value chain by Benteler(cast house / tool shop / production)

• Competitive cost / weight ratio

SOP 04.2015weight 1,04 kg (w.o. bush)axle load 1180 kg (D-Segment)

SOP 02.2015weight 1,46 kg (w.o. bush)axle load 1850 kg (E-SUV)

BMW Platform Hood Lock

variable thickness (6060-T6)

th.2

.2

TEB – Series Assembly Example

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5xxx sheet replaced with Variable thickness profile 6xxx

© BENTELER-Gruppe | Seite 17

Thank you for your Attention

Sivanathan.Prasoody@benteler.com