an effective addition to aluminum and engineering...

MnE21® manganese sheet: An effective addition to aluminum and engineering plastics

- new materials require new processes

Dr. Stephen Rudzewski

Head of Technics Germany Semcon Holding GmbH & Co. KG

24. April 2012

Index

MnE21 - New materials require new processes

1

2

Intro: Light weight design betwixt ecology and cost

Important characteristics of MnE213

Examples of real MnE21 parts 4

2 Dr. Stephen Rudzewski,

Um dieses Ziel zu erreichen muss man:

Ø ganzheitlich denken

Ø querdenken

Ø oder auch einfach ganz anders anfangen …


Introduction … Light weight design betwixt ecology and cost

Ökologie bedeutet u.a.:

Den notwendigen Rohstoff- und Energieeinsatz so intelligent miteinander zu verknüpfen, dass maximale Ressourcenschonung möglich wird.

Introduction … Sea water desalination as a source for light weight structural components


Heat & sun

Energy

Sea water

Sea water desalination

Drinking water

Basic

factor

Natrium

Chlor

Kalium

Calzium

Magnesium

Schwefel

Fluor

Indium

Lithium . . .

Salt Industry

Fertiliser-

Food-

Elektronic-

Metal- . . .

Source of picture: www.fotolia.de

Introduction … Sea water desalination as a source of immense raw materials


Salt

17 Mio t/year

Sea water

500 Mio t/year

• 9700000t Chlor

• 5400000t Natrium

• 645000t Magnesium

• 425500t Schwefel

• 206000t Calzium

• 199500t Kalium

• 650t Fluor

• 90t Lithium

• 60t Rubidium

• 10t Indium

• 1,6t Uran

. . .

But!!

What is a construction

material without

effective processes to

manufacture products?

It‘s only a substance!

Example Israel: Predicted demand for drinking water in 2020 approx. 2670 Mio m3/year Thereof estimated 500 Mio m3 from sea water desalination

Source of picture: www.fotolia.de

Index


1

2





Raw material

MnE21 - New materials require new processes …. Actual metal sheet production chain: Example engine hood

Pit

Metal-slab

Roller mill

Metal blank Metal-slab

-90%

slice

Furnace

Production plant

Press tool Metal blank

Inner structure

Assembly

gluing, riveting,

spot welding,

laser welding

etc.

Classical

aluminium or

steel hood


Sou

rce

of

pic

ture

: In

tern

et;

Sto

lfig

®

Pit

Raw material

MnE21-Pellets

MnE21 - New materials require new processes … Overview of the „ideal“ MnE21 process

Furnace

Production plant

Stud

Inner structure

Stud casting

Extruder

Press tool Metal blank

Assembly

gluing, riveting,

spot welding,

laser welding etc.

Slice

30%

-10%

70%

Aluminium-

MnE21

composite hood


Sou

rce

of

pic

ture

: In

tern

et;

Sto

lfig

®

MnE21 - New materials require new processes … Inline metal sheet production with the “Stolfig” extruder

● Metal sheets up to 1,8m width

● Continuous tailored blanks

● Heat of extruder directly used for

forming process

● MnE21 properties directly

adjustable by extruder

parameters

● Complete sheet production unit

fits in the space of a classical

“coil-unit” (~18m)

Benefit

No expensive roller mills anymore

Grading device

Tube opening

Extruder head


Source of picture: Internet; Stolfig®

Druckguss

MnE21 - New materials require new processes … almost any kind of semi finished part producible

● Metal sheet, cross-section, cast

and wire producible in house

● Even complex designs can be

realised cost and weight optimal

● Welding process with same

material filler wire is a big benefit

for corrosion and strength

● Mono-material parts possible Benefit

Filler wire 1 to >5mm

Any profiles

stepless sheet thickness

MnE21 casting

Perfect eco-friendly

recycling



MnE21 - New materials require new processes … warm manufacturing with „inline“ metal sheet production

● Stamping forces only ~20 %

● Only small presses

● Lightweight, cheap tools

● Only few pressing stages,

example 6 instead 16

● Optimal contour accuracy

● Almost no stamping flanges

necessary

● No lubricant

● No free punches necessary

● Tool cleaning with citric acid or

vinegar

Benefit

- 70%

CO₂



MnE21 - New materials require new processes … assembling and subsequent processing

Benefit

● No aging or time dependend

material properties

● Suitable for cataphoretic coating

● Material mix e.g Steel/MnE21

possible

● Assembly with „all“ known

mechanical processes

● Tempered welding with all

processes

● Robust glueing process

„without“ pre-processing

● Parts cleaning with vinegar or

citric acid

Punch riveting

Clinching

Riveting Stud welding

Rivet nut Spot welding

Bonding

TIG (8l/min Ar)

Complex welding parts Laser welding up to

20m/min) Weld joints between MnE21

and zink-plated steel

Material mix Al – MnE21

Stahl – MnE21 No free punches Cataphoretic coating

Geometrically perfect manufacturing“over“

compensates lower stiffness



Assembly

MnE21 - New materials require new processes … only the sum of innovations makes the jump

gluing, riveting,

spot welding,

laser welding,

TIG welding etc. T

Tool

150°C-350°C

Extruder

Stud press

Furnace



Index


1

2





Important characteristics of MnE21 … a good compromise of weight and strenght


Youngs modulus (GPa) 45 (Al~74) Density (g/cm³) 1,74 (Al~2,70) Melting temperature (°C) 650 (Al 660) Strenght (MPa) RP0,2=110-(>200); Rm=150-(>400) at >15% plastic strain

Isotropic in the linear elastic area, but anisotropic behavior in the plasticity area.

Has be taken into account to achieve feasible designs!

Important characteristics of MnE21 … the classical prejudices

Fire hazard

Up to 550°C

in ambient

air! NO! Because

no Mg-Al

eutectic

Heavy

corrosion

NO! If no Fe-

impurity

AZ31 MnE21

240h

Salt test

480h !

Salt test

1

!!!

st SSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSSS

Expensive NO! If

appropriate

process

MnE21-engine hood

structure can be same

price as steel structure

Bad CO²

rating

NO! If

appropriate

process

10t CO²/t MnE21

achievable


Source of picture: Stolfig®

Important characteristics of MnE21 … a promising cost structure and good eco-friendlyness


Cost (€) per kg MnE21 as raw material ~5,- € Cost per part compared to Aluminium Faktor 2 – Faktor 0,5 CO² / t with state of the art Pidgeon process < 20 tons (PE-International)

Today

Cost (€) per kg MnE21 as raw material < 2,- € CO² / t with latest furnace process < 10 tons

2020

Index


1

2





Examples of real MnE21 parts … the „ideal“ MnE21 process chain is well-proven with many sample parts

Roof cross beam: 0,52kg (1,14kg)

Door crash beam: 0,8kg (1,86kg)

IP-beam: 2,8 kg (7,2kg)

Filler wire

Engine hood structure: 2,5 kg (5,58kg)

Trunk lid inner: 1,53 kg (3,84 kg)

Seat pan: 300g (997g)

Section of door inner part

Seat pan: 305g (> 1200g)



Tongji Uni-Shanghai

Forschungsfahrzeug Bj. 2007

Antrieb: Brennstoffzelle

Stolfig-Rahmen MnE21

Rahmengesamtgewicht: 27 kg

(Stahl: 100 kg)

Examples of real MnE21 parts … E-mobility can be the ideal use case for MnE21



Examples of real MnE21 parts … many parts are already realized in a show car

Roof

rear cross

beam

0,4 kg

Roof

middle cross

beam

0,46 kg

trunk lid hinge

modul

le+ri

each 0,37 kg

Roof

front cross

beam

0,52 kg

IP-Beam

ZSB

2,6 kg

Hood hinge

Modul

le+ri

each 0,2 kg

Rear door

crash beam

le+ri

each 0,6 kg

Front door

crash beam

le+ri

each 0,8 kg

Fender braket

le+ri

each 0,14 kg

rear panel

top edge modul

2,67 kg

Back rest

5,22 kg

Rear doorFront doorFender braket

Front door

beam

0,46 k

beam

0,52 kg kg

0,46 k52525252525252525252525252525252525252525252525252525252525252525252525252525252525252 kg 0,4 kg kg 464646464646464646464646464646464646464646464646464646464646464646464646 k k k k k k k k k k k k k kg4 kgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkgkg ch 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0,37

Rear bumper

beam

1,99 kg

Trunk lid

inner structure

modul

1,53 kg

7 kg7 kg

inne

Weight saving:

> 36 kg

Fire wall

mounting plate

1,36 kg

Engine hood

inner structure

modul

2,5 kg

Front bumper

beam

1,78 kg

Front door

top edge

reinforcement

le+ri

each 0,61 kg

Front door

top edge

reinforcement

le+ri

each 0,32 kg

Reinforcement

mounting block

le+ri

each 0,08 kg


Source of picture: Internet

Semcon going next steps in structural MnE21 parts … an innovative B-post concept as a laboratory for manufacturing technology

Concept background and

targets

● Substitute for steel post in Al-space frame

● „Mono block assembly“ of

all parts by laser welding

● High quality, low tolerance laser welds by use of “hot

plasticity effect”

● Low tolerances through warm and tempered assembly

● Inner reinforcement in hot (~400 C) impact extrusion technique > „bionic“

shaping

● And some more ideas… Picture: Frankfurt Motor Show Semcon Booth 16.9.2011

First handmade show part < 8 weeks


Source of picture: Semcon

Summary: … Magnesia/MnE21 will become a new branch in the light weight arena again


Aluminium / plastic

Steel / plastic

Aluminium / steel body

BWM 5er

AC C Karosserie

unibody

steel spaceframe

composite construction

Fiat Multipla

CFRP-Monocoque

hybrid body

plastic body

steel body

aluminium body

aluminium spaceframe chassis

aluminium spaceframe hybrid construction

unibody construction

Lotus Elise

Audi

A2

Jaguar XJ

Magnesia/MnE21 Structure - the new branch

Source of picture: Internet, Semcon

Summary: … Magnesia/MnE21 will become a new branch in the light weight arena again


It is not the question IF magnesia/MnE21 will be used in large-area structural parts

but

only WHEN!

Contact

Dr. Stephen Rudzewski Technikleiter Deutschland

Semcon Holding GmbH & Co. KG Neuhartshöfe 3 85080 Gaimersheim

Telefon +49 (8458) 3289 709 Mobil +49 (172) 3781 568 [email protected] www.semcon.com


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