Sophisticated materials like high strength steel or even multi phase steel as well as aluminum require more efforts within the manufacturing process than conventional steel sheets as they have been used in the body in white recently. The manufacturing process itself as well as engineering of the parts, material of the forming tools as well as cold and warm joining technologies must be regarded separately. For forming tools coated steel inserts or sometimes even cooling is essential in terms of high-volume car series production. In mixed material solutions using steel in combination with aluminum, the common used resistance spot welding process does not work any more. To maintain high process stability of cold joining technologies combined with adhesive bonding a new process must have been developed. Other items for weight and cost savings are tailored rolled blanks or sophisticated joining technologies. Regarding the manufacturing costs, a cost effective combination of the mentioned high-sophisticated alloys with conventional material should be achieved. Developing a design concept due to crash, stiffness and driving performance, basic requirements have to be considered. This aims to check the high potential of cost intensive materials wherever high functional benefit is necessary under commercial aspects. Advanced high strength, ultra high strength steel grades as well as aluminum or in some special cases even plastic or carbon fiber can be used to solve the conflict in between weight increasing efforts for passive safety and comfort on the one hand and driving performance and fuel consumption on the other hand. To handle the new materials within the process chain press shop body in white painting/corrosion several issues of the material in combination with coatings and lubrication have to be taken into account. These may be press forces, design of tools, joining technologies as well as adhesion of adhesive bonding and corrosion. Last but not least the average minimum yield strength R(p0,2) of a body in white can be taken as a value to show the development of steel grades over a longer period of time. Due to increasing demands on cars for crash, drivability as well as power and torque of the engines it can be assumed that the average minimum yield strength R(p0,2) of a body in white will increase with the next car concepts e.g. the proportion of higher strength and ultra high strength steel grades will increase. Thus there will be a higher demand for new steel grades with high yield strength, good formability and, in terms of weight saving, a thin thickness of the sheet.
Manufacturing of high strength steel and aluminum for a mixed material body in white
Herstellung von hochfestem Stahl und Aluminium für eine Rohkarosserie aus verschiedenen Materialien
2005
16 Seiten, 22 Bilder, 15 Quellen
Conference paper
English
hochfester Stahl , Aluminium , Stahlblech , Karosserie , Formgebungswerkzeug , Beschichtung (Überzug) , Presswerkzeug , Kühlen , Punktschweißen , Kleben (Verbinden) , Kosten , Gewichtsverminderung , ultrahochfester Stahl , Kunstfaser , Kohlenstoffaser , Sicherheit , Kraftfahrzeug , Treibstoffverbrauch , Pressdruck , Korrosion , Streckgrenze , Schichtdicke , Fügetechnik
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