great designs in steel febr 04 peg-vm page 1/media/files/autosteel/great designs in steel... ·...

Great Designs in Steel 040209Pr_Lightweight_e

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January 04Company PresentationPEG_E

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Great Designs in Steel

Porsche Engineeringdriving identities

Advanced high strength steel technology in the Porsche Cayenne


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Agenda

High- and ultra-high strength steels

Application in Porsche cars

Formability

Joining technologies

Tailor-welded blanks

Hydro-Forming

Conclusion


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0

20

40

60

80

100

Am

ount

/ %

model year

Utilization of High-Strength Steel in the Body Structure

6593

3318

1992PorscheCarrera

1996PorscheBoxter

1998UlsabStudy

2002PorscheCayenne


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ULSAB - Body structure


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60

Magnesium

Aluminium

Bake Hardening

DC 04-06

0

10

20

30

40

50

0 100 200 300 400 500 600Yield Strength [MPa]

Tota

l Elo

ngat

ion

A80

[%]

HSLA/CP

Dualphase

Trip

DX 53-54

Mild Steel

High Strength Steel

Stainless Steel

Ultra High Strength Steel

Yield Strength vs. Elongationof different Materials


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Agenda



Formability



Hydro-Forming

Conclusion


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Porsche Carrera

67,2%Mild steels St05Z…St06Z

25,7%High strength steels ZStE180BH…340Z

5,1%Tailor-welded blanks

2%Boron alloyed steels

Tailor-welded blank- rear rail

Dashpanel with boron alloyed steel reinforcement


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Porsche Cayenne -

DP600

CPW900ZStE380

Trip700

Steel material types:

Body structure Structural Members


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28%Micro-alloyed- and BH-steels(ZStE180BH…H340LAD)

20%DP600 / H340X

3%BTR155

1%others

6%Tailor-welded blanks(H340LAD / H340X)

4%Trip 700 / RA-K40/70

36%Mild steels (DX…, DC…)

2%CPW800

Porsche Cayenne -Steel Material Distribution


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Rocker area with

reinforcement tube

A- and B-Pillar in

ultra high strength steel

Porsche Cayenne -Bodyside Inner Subassembly


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Agenda


Formability



Hydro-Forming

Conclusion



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Inner panel

Material thickness:

1,5 mm/ 0,06”

Material type:

Trip700

Reinforcement

Material thickness:

1,0 mm/ 0.04”

Material type:

Trip700

Porsche Cayenne - B-PillarUltra High Strength Steel


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Material thickness:

2,0 mm/ 0.08”

Material type:

DP600

Material thickness:

2,5 mm/ 0.098”

Material type:

DP600

Porsche Cayenne - Rear RailUltra High Strength Steel - Tailor-Welded Blank


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Material thickness:

2,0 mm/ 0.08”

Material type:

CPW800

Porsche Cayenne - Seat Cross-MemberUltra High Strength Steel


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Agenda




Hydro-Forming

Conclusion


Formability


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spotwelding 5782 spotsmetal-arc welding 14,11 m 64 feetmetal-arc brazing 1,52 m 4 feetlaser welding 10,15 m 33 feetlaser brazing 3,73 m 12 feettailor-welded blank seams 2,30 m 7 feet

Joining Methods in the Body Structure

Porsche Cayenne

welding processes in thebody structure

number/ length


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27%Sealing- and strength bonding

31%Structural bonding

13%Mastic bonding

14%Hem-flange bonding

15%Seal bonding

Bonding Material Types (total length 393 feet)

Porsche Cayenne


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Agenda




Hydro-Forming

Conclusion


Formability


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Material thickness:

2,5 mm/ 0.098”

Material type:

ZStE340

Material thickness:

2,75 mm/ 0.108”

Material type:

DP600

Material thickness:

3,0 mm/ 0.118”

Material type:

ZStE340

Front Rail Outer Panel

Porsche Cayenne - Tailor-Welded Blank


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Porsche Carrera

ULSAB

Porsche Cayenne

1,5mm/ 0.059” 2,0mm/ 0.079” 1,2mm/ 0.047”(140MPa) (140MPa) (300MPa)

1,6mm/ 0.063” 1,3mm/ 0.051” 1,0mm/ 0.039”(350MPa) (350MPa) (350MPa)

2,5mm/ 0.098” (380MPa) 2,0mm/ 0.079” (380MPa)

Tailor-Welded BlanksRear Rail


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0,9 mm 280 MPa

1,7 mm 350 MPa

0,7 mm 210 MPa

1,5 mm 350 MPa

1,3 mm 280 MPa

ULSAB - Tailor-Welded BlankSide Outer Panel

1,5 mm/ 0.059“350 MPa 1,3 mm/ 0.051“

280 MPa

1,7 mm/ 0.067“350 MPa

0,9 mm/ 0.035“280 MPa

0,7 mm/ 0.028“210 MPa


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Agenda




Hydro-Forming

Conclusion


Formability


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Porsche Boxster - Hydro-FormingRollover Bar Protection System


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ULSAB - Hydro-FormingSide Roof Rail

Made from tube:

Outside diameter: 96 mm/ 3.78”

Material thickness: 1,0 mm/ 6.039”

Total length: 2700 mm/ 8 feet

Yield strength: 260 MPa


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Agenda




Hydro-Forming

Conclusion


Formability


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60,00

Benchmark Benchmark Benchmark Porsche

car A car B car C Cayenne

model year 1997 model year 2000 model year 1998 model year 2003

1. Torsional- and 1. Bending-Frequency of SUV with Monocoque-Type Structure Design

tors

iona

l-an

d be

ndin

g-fre

quen

cy [H

z]

bend

ing

tors

ion

bend

ing

tors

ion

bend

ing

tors

ion

bend

ing

tors

ion


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0

5000

10000

15000

20000

25000

30000

35000

40000

Benchmark Benchmark Benchmark Porsche

car A car B car C Cayenne

model year 1997 model year 2000 model year 1998 model year 2003

Torsional-Rigidity of SUV withMonocoque-Type Structure Design

tors

iona

l-rig

itidy

[Nm

/°]


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