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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 1
Material Trendsin Automotive Applications.
Dr.-Ing. J. Staeves
Metals and Coatings
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Wichtige Anforderungen und Einflüsse auf einFahrzeugkonzept
Material Trends in Automotive Applications.
Contents.
Requirements to Materials in Automotive Applications
Car Body Shell
Car Body Structure
Engine
New Materials
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 3
Energy Management
Reliability
Safety
Economy
Drivers Workplace
Quality rating
Driving Pleasure
Environment• Emissions• Recycling• Directive on end • of live vehicles
Lightweigth Design
Material Trends in Automotive Applications.
Requirements to Automobiles.
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Wichtige Anforderungen und Einflüsse auf einFahrzeugkonzept
Material Trends in Automotive Applications.
Contents.
Requirements to Materials in Automotive Applications
Car Body Shell
Car Body Structure
Engine
New Materials
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 5
Aluminium Bonnet: -10 kg
Thermoplast Fenders (PPE+PA): -4kg
Sheet moulded Compound
Deck Lid (SMC): -2 kg
Aluminium Doors: -10 kg
Car Body Shell.
Materials for the BMW 6 Series.Weight savings compared to Steel
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 6
Car Body Shell.
Aluminium and Steel.
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 7
Car Body Shell.Aluminium and Thermoplastic.
BMW 5 Series
(Aluminium)
BMW 6 Series
(Thermoplastics)
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 8
AM50 HP, pressure diecasting
Car Body Shell.
Cast Magnesium.BMW 3 Series Convertible.
•Lightweight design
•Optimised stiffness•Reduced number of parts•Integrated fastenings
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 9
Car Body Shell.Sheet Moulded Compound (SMC).Deck Lid BMW 6 Series.
•Lightweight design•Complex shape
•Integrated antennasAM, FM, Diversity, TV, Tel, GPS,
SDARS, digital Tuner
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 10
High-class surface
SealingSMC
PUR
PUR-GFSeal
Acoustic insulation
Textile
PUR-FoamFoil
Car Body Shell.Polyurethanes.Folding Top BMW 6 Series.
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 11
3,85 kg/PS
-110 kg = 1385
neu geformte Heckklappe aus Sheet Moulding Compound (SMC)
Heckdiffusor aus CFK.
Dach CFK Sichtoptik –6 kg
wie etwa den Baustoff Endlosglasfaser-Thermoplast für die Trägerstruktur der Durchlade und den
hinteren Stossfängerträger. Oder die Papierwaben-Sandwichplatte für den Gepäckraumboden - wie
schon der M3 hat auch der M3 CSL außerdem eine Motorhaube aus Aluminium,
360 PS (265 kW) Leistung bei 7 900/min holten die M Ingenieure aus 3,2 Liter Hubraum, das ergibt
einen sensationellen Wert von 111 PS/L. Das maximale Drehmoment beträgt 370 Nm bei 4
900/min. Diese neue Ansaugluftführung mit ihrer extrem großen Ansaugöffnung und dem großen
Luftsammler aus Kohlefaser
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Wichtige Anforderungen und Einflüsse auf einFahrzeugkonzept
Material Trends in Automotive Applications.
Contents.
Requirements to Materials in Automotive Applications
Car Body Shell
Car Body Structure
Engine
New Materials
![Page 13: Material Trends 12. Okt. 2004 Page 1 in Automotive ... · Material Trends in Automotive Applications EP-530 12. Okt. 2004 Page 26 Material Trends in Automotive Applications. Conclusions](https://reader036.vdocuments.net/reader036/viewer/2022081404/5f040bc47e708231d40c0cea/html5/thumbnails/13.jpg)
Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 13
Car Body Structure.
Ratio of High Strength Steel.
High Strength Steel (min. Yield strengt 180 MPa)
0
10
20
30
40
50
60
70
80
90
100
1975 1980 1985 1990 1995 2000 2005
Year of production
Weig
ht
Rati
o [
%]
Multi Phase Steel (min. Yield strengt 300 MPa)
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 14
Standard-high-strength steel
63%
Multi-phase-
steel 16%
others 3%
Car Body Structure.
High Strength Steel.BMW 1 Series.
Other steel
DX 54
DX 56
180 MPa
220 MPa
260 MPa
300 MPa
340 MPa
380 MPa
400 MPa
420 MPa
500 MPa
680 MPa
950 MPa
Deep-drawing-quality 19%
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 15
SteelOther Steels
DC 03/04/06
DX 54
DX 56
180 MPa
220 MPa
260 MPa
AluminiumAlMg3,5 Mn
AlMg3,5Mn0,5
AlMg4,5Mn0,4
AlMg4,5Mn0,4 H24
AlMg0,4Si1,6
AC-300 HF
AlMgSi
AlMgSi1
Cast
Car Body Structure.
Aluminium Front End / Steel passenger Cab.BMW 5 Series.
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 16
Car Body Structure.
Aluminium Front End.
BMW 5 Series.
48 Al - Bolts
2,94 m Al- MIG-Weld
15,2 m Adhesive
599 Rivets
1,74 m Laserweld
Hydroformed tubeCast suspension dome
Extruded engine cradle
Stiffening bar
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 17
Car Body Structure.
Cast Magnesium Instrument Panel Carrier.MINI.
1 cast component includes mounts for
• Air ducts• steering column• Airbag module, ...
Welded carrier includes 15-25 parts
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Wichtige Anforderungen und Einflüsse auf einFahrzeugkonzept
Material Trends in Automotive Applications.
Contents.
Requirements to Materials in Automotive Applications
Car Body Shell
Car Body Structure
Engine
New Materials
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 19
1980 1990 2000 2004
Petrol
Engine.
Crank Case Materials.
GJL (grey cast iron)Al+GJL-LinersAlusil
Al-Mg
Diesel GJL, GJV (vermicular graphite)
M GG AlusilGJL
Inline-6 M Engine
Grey Cast Iron
Inline-6Petrol engineAl+GJL-liners
Inline-6 Petrol engine
Al-Mg Composite
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 20
Engine.Composite Aluminium-Magnesium Crankcase.
Aluminium insert
Magnesium
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 21
Chain wheel Stator
Rotor
• Weight saving compared to steel 800g
• High Si-ratio for wear resistance
• Sinter to achieve low tolerances and low number of mashined surfaces(cost efficiency)
Engine.Aluminium Sinter.Variable Camshaft Actuator.
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 22
Engine.
Increasing Ratio of heat resistant Plastics.
Inlet manifold Cylinder-head cover
Acoustic absorber Belt pulleyDuct für oil dip stickOil pipe
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Wichtige Anforderungen und Einflüsse auf einFahrzeugkonzept
Material Trends in Automotive Applications.
Contents.
Requirements to Materials in Automotive Applications
Car Body Shell
Car Body Structure
Engine
New Materials
![Page 24: Material Trends 12. Okt. 2004 Page 1 in Automotive ... · Material Trends in Automotive Applications EP-530 12. Okt. 2004 Page 26 Material Trends in Automotive Applications. Conclusions](https://reader036.vdocuments.net/reader036/viewer/2022081404/5f040bc47e708231d40c0cea/html5/thumbnails/24.jpg)
Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 24
Requirements to Materials.
Temperature Range.
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 25
Material Trends.
New Materials.
Nano materials
Smart materials•Shape memory alloys•Magneto rheological fluids•Magnetorestrictive materials
•Piezo ceramicsMetal foams
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Material Trendsin AutomotiveApplications
EP-53012. Okt. 2004Page 26
Material Trends in Automotive Applications.
Conclusions.
• Further development of established materials• High strength steel• Aluminium and magnesium cast
• New materials and production technologies• Sinter• Foams (plastic and metal)
• Material mix: The right material at the right place• Steel / aluminium and plastics for the body• Magnesium / aluminium crankcase
• Increasing ratio of plastics• Heat resistant plastics for the engine• Versatile material properties for the folding top
• Nano - materials and multifunctional materials are becomingincreasingly significant in automobile technology