Global Automotive Lightweight Materials 24.4.2013, London Dr. Johannes Staeves
THE RIGHT MATERIAL AT THE RIGHT PLACE. THE NEED FOR A STRATEGIC REDEFINITION OF THE MATERIAL MIX FOR A MORE ECONOMICAL AND ECOLOGICAL APPLICATION OF LIGHTWEIGHT MATERIALS.
THE RIGHT MATERIAL AT THE RIGHT PLACE. CONTENTS.
Global Trends in Automotive Industry. Challenges for Automotive Lightweight Materials. • Optimization of Materials • New Materials • Hybrid Materials Multi Material Design. Conclusions.
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
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GLOBAL TRENDS IN AUTOMOTIVE INDUSTRY PUSH THE DEVELOPMENT OF E-MOBILITY.
Environment Climate change and subsequent damage
Urban Growth
Politics
More than 60% of the worlds population will live in cities in 2030
CO2 – Taxes, Congestion charges
Demand for E-Mobility
Economy
Culture
Customer Demands
Consumption of resources, costs of fossil fuels
Sustainable mobility, social responsibility.
Change of moral concepts, demographic trends
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
NEW DRIVE CONCEPTS REQUIRE NEW LEIGHTWEIGHT MATERIALS.
EFFICIENT DYNAMICS
Optimisation
Hybrid
Electric
Hydrogen
Further development of petrol and diesel engines, innovations for even better fuel consumption figures.
Intelligent combination of electric motor and combustion engine.
All-electric driving and plug-in hybrid technology.
Long-term option for mobility with zero emissions.
today BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
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TECHNOLOGICAL SUBSTITUTION. EACH TECHNOLOGY WILL BE REPLACED. Basis for success for tomorrow
strategically critical Area
Basis for today’s success
Growth, level of technologigal development
Time Advantage in competition for old technology
Product Process
Substitution
Light sensitivity of film Film processing
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Advantage in competition for new technology
Storage capacity, chip quality
Example: digital photography
Direct printing, digital devices
Quelle: S-Kurven nach C. Marchetti; Beispiele nach F. Malik - „Gezeiten der Großen Transformation 21“, m.om.-Letter 08/10
TECHNOLOGICAL SUBSTITUTION. LINEARE EXTRAPOLATION IS NOT THE RIGHT WAY TO FACE CHALLENGES. Basis for luccess for tomorrow
strategically critical Area Linear extrapolation: Threatening the very existence of firms
Growth, level of lechnologigal levelopment
Time Advantage in competition for old technology
Substitution
Advantage in competition for new technology
The most beautiful Clippers … … just before their displacement by steam boats BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
TECHNOLOGICAL SUBSTITUTION. EVOLUTION OR REVOLUTION. Revolution?
Evolution?
Growth, Level of Technological Development
Time Advantage in Competition for old Technology
Substitution
Advantage in Competition for newTechnology
“I believe in the Future of the Horse. Automobiles will be a temporary occurrence” [Emperor Wilhelm II. ~ 1900]
"Nuclear powered vacuum cleaners will probably be a reality within 10 years." [Alex Lewyt, President of the Lewyt Vacuum Cleaner Company]
“640K is Enough For Anyone.” BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
[supposed: Bill Gates 1981] Quelle: Voest Alpine Magazin 2004
THE RIGHT MATERIAL AT THE RIGHT PLACE. CONTENTS.
Global Trends in Automotive Industry. Challenges for Automotive Lightweight Materials. • Optimization of Materials • New Materials • Hybrid Materials Multi Material Constructions. Conclusions.
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
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CHALLENGES FOR AUTOMOTIVE LIGHTWEIGHT MATERIALS.
Sustainability
Availability
CO2 – footprint, cost effectivness, social responibility
Grades, Quality and Costs
Material Restrictions End-of-Life Vehicle Directive, REACH.
Challenges for Lightweight Materials
Optimisation of Materials Formability, Strength
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Integration of New Materials Carbon fiber
Development of Hybrid Materials The right material at the right place
THE RIGHT MATERIAL AT THE RIGHT PLACE. CONTENTS. Global Trends in Automotive Industry. Challenges for Automotive Lightweight Materials. • Optimization of Materials • New Materials • Hybrid Materials Multi Material Constructions. Conclusions.
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
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OPTIMISATION OF LIGHTWEIGHT MATERIALS. FORMABILITY. Perspective
Tomorrow
Today
Yesterday
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
OPTIMISATION OF LIGHTWEIGHT MATERIALS. EACH MATERIAL PROVIDES SPECIFIC ADVANTAGES AND RESTRICTIONS. Steel duktile
Specific Strength
Aluminium
HSS
UHSS
above 700MPa > Al
Faktor 10
Forging
Cast
Magnesium Forging
Cast
Carbon Fiber Comp. Unidirect.
Isotropic
Specific Stiffness (Tension / Compression)
Buckling, Bending, Folding Ductility (Crash)
A above 40%
Potentially TWIP 60%?
Formability / Integral Construction Material Costs and Availability
Costs Target Material -50%, Cost Target Process -90%
Creep and Temperature resistance Body
Complex Geometry
Crash
Chassis
Beams, Wishbones
Suspension
shafts
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Pillars
Doors, Bonnets
Integral Components
Beams
Connections Crankcase
Interior
Interior
Body Structure
Body Structure Advantage
Crankcase
Chance for Optimisation? Restrictions Seite 12
OPTIMISATION OF LIGHTWEIGHT MATERIALS. THE DEMAND FOR LIGHTWEIGHT DESIGN PUSHES AND ENABLES MORE COSTLY SOLUTIONS.
HotFormed Steel
Carbon fiber Composites High strength Steels Magnesium Sheets
Aluminium Sheets for Doors, Bonnets and Roofs
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Tailored Solutions
Integral Parts Cast Aluminium
Integral Parts Cast Magnesium
Page 13
THE RIGHT MATERIAL AT THE RIGHT PLACE. CONTENTS.
Global Trends in Automotive Industry. Challenges for Automotive Lightweight Materials. • Optimization of Materials • New Materials • Hybrid Materials Multi Material Constructions. Conclusions.
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Page 14
THE EFFORT FOR THE CONVERSION AND THE SYSTEM-DEPENDANT ADDITIONAL WEIGHT OF THE DRIVE CHAIN CAUSE A SIGNIFICANT INCREASE IN WEIGHT.
Weight
MINI E
MINI Cooper
Effort for Conversion
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
System-dependent additional Weight of the Electric Drive Chain
LIGHTWEIGHT-APPROACH project i : THE LIFE-DRIVE CONCEPT WITH ALUMINIUM-CHASSIS AND CFRP- BIW REVERSES THE SPIRALING TREND OF INCREASING WEIGHT.
Weight
No Effort for Conversion
Comparable Car with Combustion Engine
System-dependent Lightweight-Approach: additional Weight of the LifeDrive Concept Electric Drive Components with Aluminium and CFRP compensates the additional Weight of the Electric Drive
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Electric Vehicle MCV
INTRODUCTION OF NEW MATERIALS. ACCESS TO THE COMPLETE PROCESS CHAIN. Fiber
Joint Venture SGL ACF
Precursor (PAN, spool)
Oxidation carbonisation
Surface treatment, sizing
Textile Fiber (Spool)
Non-woven fabric (reel material)
Recycling(mat) dry fiber
BMW
Preform
Bauteil (RTMProzess)
Moses Lake, USA
Stack production (Layer structure of the component)
Preforming
Trimming of the preform (Punching)
Tailoring (multiple preforms)
Injection of resin RTM
Machining (CNC / waterjet)
Wackersdorf, Germany
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Landshut/Leipzig, Germany
INTRODUCTION OF NEW MATERIALS. PRODUCTION OF NON-WOVEN FABRIC. Wackersdorf, Deutschland
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
INTRODUCTION OF NEW MATERIALS. ADAPTION OF MATERIALS TO THE AUTOMOTIOVE REQUIREMENTS.
3K Fibers
50K Fibers
Woven fabric (Exterieur)
Braiding and non-woven fabric (Structure)
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
THE RIGHT MATERIAL AT THE RIGHT PLACE. CONTENTS.
Global Trends in Automotive Industry. Challenges for Automotive Lightweight Materials. • Optimization of Materials • New Materials • Hybrid Materials Multi Material Constructions. Conclusions.
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
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HYBRID MATERIALS. THE COMBINATION OF DIFFERENT MATERIALS ALLOW FOR NEW MATERIAL PROPERTY PROFILES. AluminiumAluminiumSandwich
1+1=3!
SteelAluminiumcable rope AluminiumSilicium (Alusil)
Corrosion resistance of AlMg1
Strengt of AlMg6
Quelle Novelis
Carbon fiber with copper
Ste e l d u k t i l e
Sp e cific Stre ngth
Aluminium wheel with vermiculie core
Quelle Univ. Karlsruhe
Al u m inium
H S S
U H S S
a b o ve 700M Pa >Al
F a ktor 10
F o r g i n g
M a g n esium
C a s t
F o r g i n g
Aluminium CFreinforced
C a rb on Fibe r Comp.
C a s t
U n i d i r e c t .
I s o t r o p i c
Sp e cific Stiff ness (Te sion / C o m p ressio n)
Bu c kling, Be nding, F olding
D u ctility (Cra sh)
A a b o ve 40%
Po te ntially TWI P 60%?
Strength of carbon fiber
F o rm ability / I ntegra l Construction
M a te rial Costs and Availabil ity
C o sts Target Materia l -50%, Cost Ta rget Process -90%
C re e p and Tempera -ture re sistance
Bo d y
C o m p lex Ge ometry
C ra sh
C h a ssis
Be a m s, Wi sh b o nes
Su sp ension
sh a f ts
Pi l la rs
D o o rs, Bonn ets
I n tegral Components
Be a m s
C o n n ections
I n terior
I n terior
Bo d y Structu re
Bo d y Structu re
Creep resistance and weldability of aluminium?
Ad va n tage
C h a nce for O ptimisa tion? C ra n kcase
C ra n kcase
Re strictions BM WG ro u p , Dr. Joh annes Staeves, G ALM, 24. 04.2013
Se i te 21
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Quelle Fraunhofer IFAM
Seite 21
THE POSSIBILITIES OF HYBRID MATERIALS AND MULTI MATERIAL DESIGN RANGE FROM THE MATERIAL STRUCTURE UP TO VEHICLE CONCEPTS. Hybrid: Composed of different types, of two fold origin, mixed. As such, it seeks to identify the strengths of different materials, to combine them and to avoid drawbacks.
Hybrid Construction Material-Mix Multi Material Design Vehicle Concept
Module
Assembly
Component
Semi-finished product
Material
Laminated Glass Live-Drive concept
Aluminium frontend
Assembled camshaft
Aluminiummagnesium crankcase
Novelis Fusion®
Coatings
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Hybrid brake disk
Sandwich material
Material structures
THE RIGHT MATERIAL AT THE RIGHT PLACE. CONTENTS.
Global Trends in Automotive Industry. Challenges for Automotive Lightweight Materials. • Optimization of Materials • New Materials • Hybrid Materials Multi Material Constructions Design. Conclusions.
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
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MULTI MATERIAL DESIGN. ALTERNATING INNOVATIONS IN MATERIALS AND PRODUCTION TECHNOLOGY ENABLE NEW DESIGNS. Before
1976
Forged
1976
Cast (solid) chill castings 4375 g
1993
Sintered cams soldered to tube 2533 g
2000
Cast (Hollow-Cast) Outlet 2160 g, Intake 2004 g
2004
Hydroformed 1351g
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Functionality with one material
Separation of functions
Integration of functions
Separation of functions
MULTI MATERIAL DESIGN. DIFFERENTIAL DESIGN IS AN ENABLER FOR THE RIGHT MATERIAL AT THE RIGHT PLACE. 1997
BMW 3 Series Different steel grades welded
2001
Mini Magnesium die-cast
Integral design
2004
BMW 3 Series Different steel grades and tailor rolled tube
Differenial design
2007
BMW X5 Magnesium-die-cast
Integral design
2008
BMW M3 - Prototype Magnesium sheet welded
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Differential design
Differential design
MULTI MATERIAL DESIGN. MULTI MATERIAL DESIGN IS A RESULT OF NETWORKED THINKING AND WORKING. Incresing customer demands Legal requirements Derivates and plattform strategies
Design Functional Principles
Multi Material Lightweight Construction Material
Constant, reliable and standardised processing properties Mastering of complex multi material constructions Short processing Times
Global availability Global aaterial atandards Sustainability Multiple suppliers BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Innovative production technologies for new materials
Production
Global production Sustainability Capacity utilisation of plants Standardised processes Seite 26
MULTI MATERIAL CONSTRUCTION. THE NUMBER OF MULTI MATERIAL JOINTS INCREASES WITH INCREASING MASTERY OF THESE PROCESSES.
BMW 3 Series Steel Conventional Stampings
Rolls Royce Aluminium Spaceframe No Steel-Aluminium-Joint BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
5 Series (Predecessor)
BMW X5, BMW 7 and BMW 5 Series
Aluminium-Frontend
Steel-Aluminium-Design
Conventional Stampings, Profiles and Cast
Stampings, Hot Formed Steel and Cast
One Steel-Aluminium Joint
Multiple Steel-Aluminium Joints Seite 27
MULTI MATERIAL CONSTRUCTION. THE LIFE DRIVE CONCEPT.
BMW i3 Concept
BMW i8 Concept
One Aluminium-CFRP-Joint BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Seite 28
THE MATERIAL STRATEGY IS TO BE BALANCED WITH THE STRATEGY FOR THE ARRAY OF PRODUCTS AND PLANTS. Klasse
Limousine
Touring
Super Luxus upper upper middle middle
compact small
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Hatch
Coupé
Cabrio
Roadster
SAV
SAC
THE RIGHT MATERIAL AT THE RIGHT PLACE. CONTENTS.
Global Trends in Automotive Industry. Challenges for Automotive Lightweight Materials. • Optimization of Materials • New Materials • Hybrid Materials Multi Material Constructions. Conclusions.
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
Page 30
THE RIGHT MATERIAL AT THE RIGHT PLACE. CONCLUSIONS. • Driving pleasure, electro mobility and sustainability push lightweight materials and cause a strong competition. Lightweight activities (minor and major), that could not be used until now - e.g. due to economical reasons - now become relevant.
• None of the today’s materials can fulfill all requirements of complex automotive structures alone. • In addition to the substitution of materials a more and more complex multi material design with hybrid materials will be necessary. Competition of materials and simultaneously the cooperation of materials • The integration of new materials requires a profound knowledge of the interaction between materials, construction, functions, functional principles, production processes, modular systems and costs and their dependence on the product portfolio and production volume. The right material, the right design and the right production technology at the right place • Bigger steps in weight reduction with lightweight materials will require new designs and production concepts including the automotive supply chain.
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013
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