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NUEVOS MATERIALES Y PROCESOS PARA LA 4ª GENERACION DE LA<br />
TECNOLOGIA DE ESTAMPACION EN CALIENTE<br />
Copyright © 2015 Gestamp<br />
8ª JORNADA DE ESTAMPACION DE AUTOREVISTA<br />
04.11.2015
AGENDA<br />
1. GESTAMP<br />
2. Presshardening Processes & Coatings<br />
3. Soft zone by flex laser tempering<br />
4. Laser addition TPP ( Tailored Process Product )<br />
©2015 GESTAMP 1<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Gestamp overview<br />
1.<br />
©2015 GESTAMP<br />
2<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Gestamp – Following Market Tendencies<br />
1.<br />
GLOBALIZATION<br />
SAFETY INCREASE<br />
LIGHTENING WEIGHT & CO2 EMISSIONS REDUCTION<br />
ENVIRONMENT :<br />
RECYCLABILITY OF MATERIALS<br />
©2015 GESTAMP<br />
3<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Gestamp – Product Development Portfolio<br />
1.<br />
©2015 GESTAMP<br />
4<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Gestamp – Low Carbon Forming and Assembly Technologies<br />
1.<br />
LIGHTWEIGHT<br />
DESIGN<br />
Process R&D<br />
CONFIDENTIAL – PROPIETARY INFORMATION OF GESTAMP<br />
©2015 GESTAMP 5<br />
This Any document use, disclosure may be or not reproduction copied, distributed, of this information modified, translated without Gestamp’ or transmitted s written without permission GESTAMP’s is a violation prior written of Gestamp’ authorization. s right.<br />
All All rights reserved.
Gestamp – Low Carbon Joining and Machining Technologies<br />
1.<br />
LIGHTWEIGHT<br />
DESIGN<br />
Process R&D<br />
©2015 GESTAMP 6<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Gestamp – Materials for Lightweight Design<br />
BIW structural solutions for weight saving:<br />
PRODUCT<br />
DEVELOPMENT<br />
1.<br />
Cost and weight optimization as main objectives…<br />
20% Weight<br />
reduction<br />
Weight<br />
Weight<br />
reduction<br />
Cost<br />
Cost reduction<br />
Hot stamping<br />
Roll-forming<br />
HSS stamping<br />
Cold stamping<br />
Time<br />
PRIO 1<br />
PRIO 2<br />
Weight Saving<br />
©2015 GESTAMP<br />
7<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Gestamp – Materials for Lightweight Design<br />
UHSS materials solutions for vehicle weight saving:<br />
1.<br />
Process R&D<br />
©2015 GESTAMP 8<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Gestamp – Materials for Lightweight Design<br />
UHSS materials innovation solutions for weight saving:<br />
1.<br />
Process R&D<br />
CONFIDENTIAL – PROPIETARY INFORMATION OF GESTAMP<br />
©2015 GESTAMP 9<br />
This Any document use, disclosure may be or not reproduction copied, distributed, of this information modified, translated without Gestamp’ or transmitted s written without permission GESTAMP’s is a violation prior written of Gestamp’ authorization. s right.<br />
All All rights reserved.
AGENDA<br />
1. GESTAMP corporación<br />
2. Presshardening processes & Coatings<br />
3. Soft zone by flex laser tempering<br />
4. Laser addition TPP ( Tailored Process Product )<br />
©2015 GESTAMP 10<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Presshardening Technology<br />
2.<br />
©2015 GESTAMP<br />
11<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Presshardening Technology<br />
2.<br />
22MnB5 Coatings :<br />
• uncoated 22MnB5 (uncoated),<br />
• AlSi-coated 22MnB5 (AlSi),<br />
• coldformed zinc coated steel (Z100)<br />
• Zn-coated material<br />
©2015 GESTAMP<br />
12<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Presshardening Technology<br />
MARKET REQUIREMENT ON PRESSHARDENING TECHNOLOGY<br />
EVOLUTION OF PHD IN TERMS OF TECHNOLOGY AND MATERIAL<br />
50%<br />
50% Weight %<br />
of BIW<br />
2.<br />
PH 1G<br />
PH 1 st Gen. [Uncoated]<br />
1%<br />
Door<br />
Beam<br />
5%<br />
FR/RR<br />
Bumper<br />
9%<br />
B-Pillar<br />
A-Pillar<br />
Upper<br />
18%<br />
Tunnel<br />
X-MBR<br />
Sill<br />
28%<br />
Local<br />
RR<br />
Rails<br />
B-Pillar Local<br />
Soft Zone<br />
FR<br />
Rails<br />
38 %<br />
©2015 GESTAMP<br />
13<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Presshardening Technology<br />
MARKET REQUIREMENT ON PRESSHARDENING TECHNOLOGY<br />
EVOLUTION OF PHD IN TERMS OF TECHNOLOGY AND MATERIAL<br />
50%<br />
50% Weight %<br />
of BIW<br />
AlSi<br />
Type of<br />
material<br />
2.<br />
PH 1G<br />
PH 2G<br />
PH 2nd Gen. [Corrosion protection]<br />
PH 1 st Gen. [Uncoated]<br />
1%<br />
Door<br />
Beam<br />
5%<br />
FR/RR<br />
Bumper<br />
9%<br />
AlSi<br />
B-Pillar<br />
A-Pillar<br />
Upper<br />
18%<br />
Tunnel<br />
X-MBR<br />
Sill<br />
28%<br />
Local<br />
RR<br />
Rails<br />
B-Pillar Local<br />
Soft Zone<br />
FR<br />
Rails<br />
38 %<br />
iPHS<br />
©2015 GESTAMP<br />
14<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Presshardening Technology<br />
MARKET REQUIREMENT ON PRESSHARDENING TECHNOLOGY<br />
EVOLUTION OF PHD IN TERMS OF TECHNOLOGY AND MATERIAL<br />
50%<br />
50% Weight %<br />
of BIW<br />
AlSi<br />
Type of<br />
material<br />
2.<br />
PH 1G<br />
PH 2G<br />
PH 3G<br />
PH 2nd Gen. [Corrosion protection]<br />
PH 3rd Gen. [Softzone]<br />
5% SZ<br />
85% AlSi<br />
PH 1 st Gen. [Uncoated]<br />
1%<br />
Door<br />
Beam<br />
5%<br />
FR/RR<br />
Bumper<br />
9%<br />
AlSi<br />
B-Pillar<br />
A-Pillar<br />
Upper<br />
18%<br />
Tunnel<br />
X-MBR<br />
Sill<br />
28%<br />
Local<br />
RR<br />
Rails<br />
B-Pillar Local<br />
Soft Zone<br />
FR<br />
Rails<br />
38 %<br />
iPHS<br />
©2015 GESTAMP<br />
15<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Presshardening Technology<br />
MARKET REQUIREMENT ON PRESSHARDENING TECHNOLOGY<br />
EVOLUTION OF PHD IN TERMS OF TECHNOLOGY AND MATERIAL<br />
PH 4G<br />
50%<br />
50% Weight %<br />
of BIW<br />
AlSi<br />
Type of<br />
material<br />
2.<br />
G<br />
Generation<br />
PH 1G<br />
PH 2G<br />
PH 3G<br />
PH 2nd Gen. [Corrosion protection]<br />
PH 3rd Gen. [Softzone]<br />
PH 4th Gen. [Laser improved ]<br />
2% Laser<br />
5% SZ<br />
85% AlSi<br />
PH 1 st Gen. [Uncoated]<br />
1%<br />
Door<br />
Beam<br />
5%<br />
FR/RR<br />
Bumper<br />
9%<br />
AlSi<br />
B-Pillar<br />
A-Pillar<br />
Upper<br />
iPHS<br />
18%<br />
Tunnel<br />
X-MBR<br />
Sill<br />
28%<br />
Local<br />
RR<br />
Rails<br />
B-Pillar Local<br />
Soft Zone<br />
NEW<br />
Gestamp<br />
FR<br />
Rails<br />
38 %<br />
ALL OEM´s<br />
REQUESTING<br />
IMPROVED<br />
CORROSION<br />
PROTECTION<br />
ESPECIAL IN<br />
WET AREA!<br />
©2015 GESTAMP<br />
16<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
GESTAMP PH TECHNOLOGY IN ONE HAND<br />
PROCESS + TOOLING + R&D RESULT<br />
GESTAMP TOOLS<br />
Gestamp unique tool design<br />
High performance dies for best<br />
process speed<br />
SOFT ZONE<br />
offers new, till today not<br />
possible solutions in crash<br />
management.<br />
NEW PRODUCTS BY COMBINED<br />
APPLICATION OF THE TECHNOLOGIES<br />
DEVELOPED BY GESTAMP<br />
2.<br />
Best production performance with<br />
< 10 sec process time!<br />
GESTAMP PRESS LINES<br />
Multi Cushion Technology for best<br />
tool contact and avoid deforming.<br />
(geom. stability)<br />
PREDEVELOPMENT<br />
offers the stamping of the<br />
part with the definitive shape<br />
, avoiding post laser<br />
operation.<br />
GESTAMP COOLING<br />
Straight cooling concept trough the<br />
die for best cooling rates in the<br />
market<br />
ONE TECHNOLOGICAL GROUP WITH RESULTS<br />
©2015 GESTAMP<br />
17<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Presshardening Technology<br />
PRESS HARDENING LINES FOOTPRINT 2015 & FORECAST 2016<br />
2.<br />
PUEBLA I<br />
PUEBLA II<br />
MASON<br />
W VIRGINIA<br />
CHATTANOOGA<br />
HAYNRODE<br />
LOUNY<br />
LUDWIGSFELDE<br />
LE THEIL<br />
BIZKAIA<br />
VALENCIA<br />
BARCELONA<br />
GOUZEAUCOURT<br />
LLANELI<br />
PALENCIA<br />
LULEA<br />
BURSA<br />
TBC<br />
SHENYANG<br />
KUNSHAN<br />
WUHAN<br />
DONGGUAN<br />
BLUE = EXISTING LINE<br />
RED = NEW LINE SET UP<br />
GREEN = GREENFIELD<br />
BETIM<br />
TAUBATE<br />
Forecast 2016<br />
24 PH Plants<br />
72 PH Production Lines<br />
35 Europe<br />
19 Nafta<br />
14 Asia<br />
3 Mercosur<br />
+ 6 Tryout lines in Toolshops<br />
©2015 GESTAMP<br />
18<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
MATERIALS PROCESS/PRODUCT<br />
DEVELOPMENT – PROCESS / PRODUCT & MATERIALS<br />
2.<br />
30 years<br />
DEVELOPMENT:<br />
ALL PROCESS TECHNOLOGIES<br />
TAILORED MATERIAL PROPERTY<br />
TAILORED MATERIAL THICKNESS<br />
QTR4/2015<br />
WIDE SCOPE OF ZN SOLUTIONS<br />
estimation<br />
not in production<br />
NO MICROCRACKS<br />
©2015 GESTAMP<br />
19
AGENDA<br />
1. GESTAMP corporación<br />
2. Presshardening Processes & Coatings<br />
3. Soft zone by flex laser ( Partial Tempering )<br />
4. Laser addition TPP ( Tailored Process Product )<br />
©2015 GESTAMP 20<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
SOFT ZONE – Partial Tempering by Flex Laser Technology<br />
3.<br />
*<br />
©2015 GESTAMP 21<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
SOFT ZONE – Partial Tempering by Flex Laser Technology<br />
Product application – HT700 Flex Laser<br />
3.<br />
©2015 GESTAMP 22<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
SOFT ZONE – Partial Tempering by Flex Laser Technology<br />
• Product application : HT700 Flex Laser<br />
It consists in obtaining tailored properties on a press hardened part<br />
thanks a laser thermal treatment.<br />
Process limitation: Laser spot size<br />
Benefit of the method:<br />
3.<br />
‣ Various material grade can be obtained: HT400, HT550 and HT700<br />
‣ Application to low thicknesses [0,8mm]<br />
‣ Narrow areas and complex pattern feasibility<br />
• Applications opportunities…<br />
…on BIW structural parts bending areas<br />
…as combination with press hardened parts<br />
Front Rails<br />
Rear Rail<br />
USIBOR1500<br />
HT700 Soft Zones<br />
A-Pillar<br />
B-Pillar<br />
USIBOR1500<br />
HT700 Soft<br />
Flanges<br />
t1.0mm<br />
HS Wheelhouses<br />
©2015 GESTAMP 23<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
SOFT ZONE – Partial Tempering by Flex Laser Technology<br />
3.<br />
©2015 GESTAMP 24<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
SOFT ZONE – Partial Tempering by Flex Laser Technology<br />
3.<br />
CONFIDENTIAL – PROPIETARY INFORMATION OF GESTAMP<br />
©2015 GESTAMP 25<br />
This Any document use, disclosure may be or not reproduction copied, distributed, of this information modified, translated without Gestamp’ or transmitted s written without permission GESTAMP’s is a violation prior written of Gestamp’ authorization. s right.<br />
All All rights reserved.
FLT FLEX LASER TECHNOLOGY FOR REDUCED SOFT FLANGES<br />
PARTIAL HARDENING PARTS<br />
• New MINI SOFT ZONES, adapted to clinching or riveting.<br />
• Transition area minimal only on flanges LESS 10MM<br />
• Own GESTAMP protected patent.<br />
• Fast solution for prototypes<br />
• New innovative solutions for design tailored to exact needs.<br />
Copyright © 2015 Gestamp<br />
3.<br />
©2015 GESTAMP<br />
26
AGENDA<br />
1. GESTAMP corporación.<br />
2. Presshardening Processes & Coatings.<br />
3. Soft zone by flex laser ( Partial Tempering ).<br />
4. Laser addition TPP (Tailored Product Process).<br />
©2015 GESTAMP 27<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Laser addition TPP ( Tailored Product Process )<br />
3.<br />
*<br />
©2015 GESTAMP 28<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Laser addition TPP (Tailored Product Process)<br />
Powder feed system (Laser Cladding):<br />
3.<br />
Metal Additive Manufacturing Processes by Laser.<br />
Powder-fed systems are also known as Laser<br />
Cladding, Directed Energy Deposition and<br />
Laser Metal Deposition.<br />
The process is highly precise and based on an<br />
automated deposition of a layer of material with<br />
a thickness varying between 0.1mm and several<br />
centimetres.<br />
The metallurgical bonding of the cladding<br />
material with the base material and the absence<br />
of undercutting are some features of this<br />
process. The process is dissimilar to other<br />
welding techniques in that a low heat input<br />
penetrates the substrate.<br />
©2015 GESTAMP 29<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Laser addition TPP (Tailored Product Process)<br />
Laser cladding for located reinforcements in structural components<br />
3.<br />
• The laser beam is used to generate a molten pool on the surface of the component. A metal powder is<br />
introduced into it to solidify, and forms a metal cord.<br />
• Normally, this technology is used to print 3D parts with a complex geometry or to repair expensive parts.<br />
• Our process is so highly localized to reinforce a structural component of boron steel increasing rigidity and<br />
improving the crash behavior.<br />
Process Scheme<br />
Macrography of a reinforcement in a sheet of<br />
boron steel<br />
Characteristics:<br />
• Sheet Metal thickness: 0,8–2mm<br />
• Sheet Metal : 22MnB5 for hot<br />
forming.<br />
Patent application<br />
©2015 GESTAMP<br />
30<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Bending Moment / Force<br />
Laser addition TPP (Tailored Product Process)<br />
• Metal additive manufacturing process by laser<br />
to reinforce BIW hot stamping structural parts<br />
4.<br />
Method of depositing material by which a powdered<br />
material is melted and consolidated by use of a laser<br />
Process limitation: dimensions of added material<br />
- Line width: 1mm to 3mm<br />
- Height of added material: 1mm<br />
Benefit of the method: Put the right material at the right<br />
place for Crash/NVH/Stiffness management<br />
Increase<br />
Stiffness<br />
Increase<br />
Loading<br />
capacity<br />
• Application opportunities…<br />
Intrusion<br />
Front Rails<br />
Rear Rails<br />
A-Pillars<br />
B-Pillars<br />
Rockers<br />
Patent application<br />
©2015 GESTAMP<br />
31<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Laser addition TPP (Tailored Product Process)<br />
4.<br />
©2015 GESTAMP<br />
32<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Laser addition TPP (Tailored Product Process)<br />
GESTAMP<br />
DEVELOPMENT<br />
OPERATIONS<br />
GESTAMP VW<br />
USIBOR1500<br />
12,5 kg<br />
4.<br />
T T E BIW<br />
TECHNOLOGY<br />
DEVELOPMENT<br />
CO DEV<br />
Technology<br />
CRASCH OPT<br />
LIGHT WEIGHT<br />
PH AND ALU<br />
NEW<br />
PH Solutions<br />
SOFT ZONES<br />
TPP Solutions<br />
AL Solutions<br />
PROJECTS<br />
ORGA<br />
EXAMPLES<br />
DP450<br />
t. 1,2mm<br />
Multi-parts<br />
Hot & Cold<br />
Stamping<br />
TWB - USIBOR1500<br />
+ DUCTIBOR<br />
DP600<br />
t. 1,2mm<br />
DP450<br />
t. 1,2mm<br />
USIBOR1500 – Tailor Rolled Blank<br />
Symmetrical Blank<br />
USIBOR1500<br />
t. 1,6mm<br />
-0,8 kg/V<br />
-7 %<br />
12,1 kg<br />
USIBOR1500<br />
t. 1,6mm<br />
DP600<br />
t. 1,2mm<br />
DP600<br />
t. 1,2mm<br />
USIBOR1500<br />
t. 1,5mm<br />
-1,9 kg/V<br />
-15 %<br />
11,1 kg<br />
USIBOR1500<br />
t. 1,8mm<br />
USIBOR1500<br />
t. 1,5mm<br />
10,3 kg<br />
-2,6 kg/V<br />
-20 %<br />
DP980<br />
t. 1,1mm<br />
? kg/V<br />
-?? %<br />
TPP<br />
(TAILORED PROCESS PRODUCT)<br />
“ FREE 3D MATERIAL<br />
THICKENING “<br />
USIBOR1500 BULL DESIGN<br />
+ Stiffener<br />
+ Soft Zone HT550<br />
BULL DESIGN<br />
CONCEPT<br />
DP600<br />
t. 1,2mm<br />
Soft Zone<br />
HT550<br />
t. 1,2mm<br />
USIBOR1500<br />
t. 1,2mm<br />
©2015 GESTAMP 33<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
Laser addition TPP (Tailored Product Process)<br />
GESTAMP<br />
DEVELOPMENT<br />
OPERATIONS<br />
GESTAMP VW<br />
USIBOR1500<br />
12,5 kg<br />
Copyright © 2015 Gestamp<br />
4.<br />
T T E BIW<br />
TECHNOLOGY<br />
DEVELOPMENT<br />
CO DEV<br />
Technology<br />
CRASCH OPT<br />
LIGHT WEIGHT<br />
PH AND ALU<br />
NEW<br />
PH Solutions<br />
SOFT ZONES<br />
TPP Solutions<br />
AL Solutions<br />
PROJECTS<br />
ORGA<br />
EXAMPLES<br />
DP450<br />
t. 1,2mm<br />
Multi-parts<br />
Hot & Cold<br />
Stamping<br />
DP600<br />
t. 1,2mm<br />
DP450<br />
t. 1,2mm<br />
USIBOR1500 – Tailor Rolled Blank<br />
Symmetrical Blank<br />
USIBOR1500<br />
t. 1,6mm<br />
-0,8 kg/V<br />
-7 %<br />
12,1 kg<br />
NEW GESTAMP TPP (Tailored Process Poduct)<br />
DP600<br />
t. 1,2mm<br />
DP600<br />
t. 1,2mm<br />
-1,9 kg/V<br />
-15 %<br />
11,1 kg<br />
USIBOR1500<br />
t. 1,8mm<br />
USIBOR1500<br />
t. 1,5mm<br />
10,3 kg<br />
-2,6 kg/V<br />
-20 %<br />
? kg/V<br />
-?? %<br />
TPP<br />
(TAILORED PROCESS PRODUCT)<br />
“ FREE 3D MATERIAL<br />
THICKENING “<br />
USIBOR1500 BULL DESIGN<br />
+ Stiffener<br />
+ Soft Zone HT550<br />
BULL DESIGN<br />
CONCEPT<br />
DP600<br />
t. 1,2mm<br />
©2015 GESTAMP 34<br />
This document may be not copied, distributed, modified, translated or transmitted without GESTAMP’s prior written authorization.<br />
All rights reserved.
5<br />
GARANTIZAR<br />
CONTINUIDAD<br />
Muchas Gracias<br />
DEFINIR<br />
ORGANIZACIÓN<br />
Y PLAN<br />
2<br />
Francesc Perarnau<br />
4<br />
Innovation & Technology Institutional Affairs Director<br />
Communication and Institutional Affairs Corporate office<br />
e.mail fperarnau@gestamp.com<br />
PREPARAR<br />
A LA ORGANIZACION<br />
3<br />
Global Solutions Components / Metal Automotive Modules<br />
“ Technology Push to market needs “
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