The Body in White of the new
Duane Copeland BMW AG
Markus Pfestorf BMW AG
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Contents
I) Introduction II) Concept of the Car III) Materials and Manufacturing Technologies
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Introduction
Coupe-Like Exterior -
Personal Space -
Semi Command Position Perfect Entry Rear Leg Room Sedan-like Separated Trunk
Coupe-Like Silhouette Frameless Doors High-Quality Appearance of Exterior (ex. chrome and high gloss black elements)
Functionality Modern, Elegant Interior - New Type of High-Quality Interior - Extended Ambient Light - Single Rear Seat Configuration (option)
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- Twin-Trunk Lid - Trunk Volume - Flexible 2 nd Seat Row / Trunk Size
Relative Product Dimensions 1678
1456
1555
2933
3070
3070
BMW X6 BMW 7 series BMW 5 series Gran Turismo www.autos teel.org
Technical Components for EficientDynamics Integral-V-Multilink Suspension
Lower CO2 Emissions
Efficient TwinPower ur o ng nes
Runflat Tires Eight Gear Automatic Transmission with Steptronic Double-Wishbone Front Axle www.autos teel.org
Light Weight Body in White Design
Torsional Stiffness and Lightweight Coefficient 40.000
4,0
Nm/°
cT
3.0
30.000
T
3,5
31,500
3,0
27,500
2.6
25.000
2,5
20.000
2,0
c s s . e n f f i t s 10.000 l a n o 5.000 i s r o T 0
L=
mGer CT x A
, 1,0 0,5 Closed Roof
[
Kg Nm/°x m²
x 10³ ]
L t n e i c i f f e o c t h g i e w t h g i L
0
Sun Roof L mGer. cT A
Lightweight Coefficient Weight of Body-in-White Torsional Stiffness Area (wheel base x track width)
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Increase of Stiffness in the Front and Rear End
High Pressure Cast Aluminum Shock Tower
Struts Aluminum Struts www.autos teel.org
Torsion Frame Steel Aluminum
Passive Safety Driving Warning Correction Crash Unavoidable Active safety
Crash
Stiffness
Post Crash Passive safety Strength
cT
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Load Path of Side Impact
B-Pillar
Impact
Hot Stamped Components
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USNCAP Barrier •Passenger Values OK •Doors Remain Closed
arr er
8 Cylinder 4-Wheel Drive (incl. simulated luggage) Load = 2555 kg
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eg t=
g
Materials Steel DC04 DX54D DX56D HC180BD, HC180YD HC220BD, HC220YD HC260BD, HC260LAD, HC260X(D) HC300BD, HC300LAD, HC300X HC340LAD, HC340X(D) HC380LAD HC400T HC420LAD, HC450X HC600C, HD680C HC700X HC1000W (+TE), HC1000WD+ZF Aluminium AlMg3,5Mn AlMg4,5Mn0,4 AlMg1/AlMg5,7/AlMg1 AlMg0,4Si1,2 AlSi0,6Mg0,5 AlSi10MgMnFe AlMgSi Others Other metallic materials
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Materials of the Structure 180 MPA 7%
200 – 220 MPa 9%
Deep Drawn Steel 19%
260 MPa 10%
Others 5%
300 - 340 MPa 21%
um num 2% 1000 MPa 12% 600 - 700 MPa 1%
380 - 450 MPa 14%
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Weight Savings Compared to Conventional Steel Grades
Hot Stamped Parts: -20,7 kg -
,
Shock Tower: -4,0 kg
Hood: -7 kg Doors: -16 kg
Total weight savings due to lightweight material design: 60,9 kg www.autos teel.org
Hot Stamped Parts B-Pillar Reinforcement Material: HC1000WD+ZF Thickness 1,80 A-Pillar Reinforcement Material: HC1000W Thickness 1,60
B-Pillar Reinforcement Inner Material: HC1000W Thickness 1,60 Longitudinal Side Member Inner Material: HC1000WD+ZF Thickness 1,50 Hinge Carrier Reinforcement Material: HC1000WD+ZF Thickness 1,60
Longituidinal Side Member Outer Material: HC1000WD+ZF Thickness 1,00
Tunnel Reinforcement Material: HC1000W+TE Thickness: 1,50
Uncoated Material Zinc Coated Material
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Press Hardening Process for Zinc Coated Boron Steel
Hot dipped galvanized coil
Cold forming
Austenizing + press hardening
Annealing (optional)
Cleaning (optional)
1. Form and Trim in a conventional cold forming process. 2. Heat up the part to Austenitizing Temperature. 3. Pressharden by Quenching in a cooled die. 4. Cleaning of the parts to remove Oxide Layer (optional).
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Oiling (optional)
Press Hardening Process for Zinc coated Boron Steel
m
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Press Hardening Process Window Increase of Oxide Layer
min. Time for Mechanical Properties
Process Window
(austenitization of the material)
max. Time for • Welding • Corrosion Protection • Paint Adhesion • Glue Adhesion content)
Oxide Layer Zn Fe Coating
Basic Material
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Barrier and Cathodic Protection A. Overview Picture: • Zinc Coated Hot Formed Steel after 10 weeks of testing
100µm
Iron
C. Undamaged Region: • Barrier and Cathodic Protection
Zinc
Zn Fe Coating 22MnB5
B. Region along the Scratch: • Cathodic Protection • No Base Material Corrosion • Corrosion Creep of Paint: 0,4mm
50µm
Conclusion: • Protection exists even with damaged surface and along cut edges • Application in wet areas without supplementary support
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Coating Properties – Zinc Distribution 22MnB5
Zn-FeLayer
10µm
10µm
Zinc-, Iron- Distribution
Conclusion: • no zinc within the base material • no Embrittlement of grain boundaries by zinc Zn-Fe Layer
22MnB5
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Other Applications of Zinc Coated Boron Steel
BMW 7 series (SOP 2008)
BMW 5 series (SOP 2010)
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Application of Dual Phase Steel
Steel Grades HC260XD HC300X HC340X(D) HC400T HC450X HC600C, HD680C
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Dachrahmen innen hinten an Serienstand angepasst 14.09.09
Work Hardening of Dual Phase Steel (HC450X) Thinning Specimen
min.
1
2 max.
Measured Yield Strength
Section 1
Section 2
Bent Part
548 MPa
557 MPa
Deep Drawn Part
767 MPa
580 MPa
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Thank You for Your Attention
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