constellium high strength crash management systems 20150609

High Strength Crash Management Systems

June, 9th - 10th

Lionel Chapis - Frank Gensty

High strength crash management systems

Introduction

Constellium key figures

Cross functional and integrated Constellium Innovation Process

RCAR Structure

High strength crushable alloys (C28 and above)

Towing

Correlation Simulation & Testing

Constellium Innovation

RCAR Bumper

High strength structural alloys (HSA6)

Constellium Innovation

Conclusion

AEE 2015 Nürnberg

9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg 2

Constellium is a leader in innovative aluminium-based

solutions


10,000 employees*

€ 4.7 billion in sales*

23 manufacturing sites

C-TEC, our world-class Technology Center

Headquartered in Amsterdam, The Netherlands.

Corporate offices in Paris, France, Zurich, Switzerland and

New York, USA

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Constellium is a market leader in Automotive Structural applications

Crash Management Systems• ~ 55% of sales

Side Impact Beams, other Safety Systems

• ~ 15% of sales

BIW Structural Parts• ~ 30% of sales

Main products

Automotive Structures


Define targets, (strength, crush,

corrosion resistance, etc.), alloy

design and process conditions

Undertake rapid prototyping

experiments - cast, extrude and

test a full range of potential alloys

Analyse data and select only the

few best candidates

Scale Up – Prototypes, process

optimisation & qualification testing

Technology / Knowledge transfer

to the extrusion plants

In house research centre (C-TEC) & Integrated R&D

Network

Lab scale DC caster & 5MN press

Full scale DC casting centre with MC & 6”

fully integrated extrusion press line

& ageing oven (*)

(*) Government funding secured in partnership with JLR to establish a Constellium University Technology Centre at Brunel University

36

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Advanced Die Design Models – Shape,

microstructure & extrudability

Re-Thinking Extrusion Alloy Design And Manufacturing Process

Alloy & Process Development


Re-thinking alloy design and manufacturing

process, permitted to combine upsides of

current 6xxx and 7xxx solutions to obtain

press-quenched high-strength 6xxx alloys

Re-thinking alloy design and manufacturing

process, permitted to combine upsides of

current 6xxx and 7xxx solutions to obtain

press-quenched high-strength 6xxx alloys

Focus on High Strength Alloys – 6xxxRe-thinking manufacturing process and alloy design

Press quench, standard billet purity

(easy to recycle), excellent corrosion

resistance, homogeneous properties

Standard billet purity (easy to recylce),

excellent corrosion resistance

Separate quench, heterogeneous

properties

Current solutions with

Rm sup. to 400MPa

Future state with

Constellium HSA – 6xxx

Press quench if no formability

requirements, homogeneous

properties

High billet purity, Stress-corrosion

cracking risk, formability guaranteed

only with separate quench

6xxx alloys (e.g. AA 6056)

7xxx alloys (e.g. AA 7108A)

+

+

-

-

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-

Constellium HSA – 6xxx

Automotive Engineering Expo 2015 Nürnberg 9th - 10th June 6

High Strength 6xxx Versus High Strength 7xxx

Extrudability/Strength Compromise


50

60

70

80

90

100

110

300

320

340

360

380

400

420

440

EX

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RM

(M

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)

Strength potential Rm (MPa) Relative extrudability

Low Speed Insurance Test

9th - 10th June 8

RCAR Structure Test

Objective of Test

• Rigid barrier in steel

• Overlap 40% of the vehicle width w/o exterior mirrors

• Impact velocity VF = 15,0 km/h ( +1/-0 km/h )

• At the moment of impact the vehicle shall be free of the propulsion system

• Test vehicle weight = curb weight with full fuel tank + additional test devices and 75 kg ballast for the driver

Objective of Development

• System with maximum efficiency of energy absorption

• No damage of cooling system (front system)

• No damage on the longitudinals

• No side collapse during crash

Automotive Engineering Expo 2015 Nürnberg

New Alloys for light weight design

C28 crushable alloy

9th - 10th June 9

0.00

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0.40

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0 0.1 0.2 0.3 0.4 0.5

True strain

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EN 6060-T62

C28

New Constellium C28 crushable alloy

YS ≥280MPa vs. 200MPa for 6060

Potential for weight savings on crush

boxes up to 20%, depending on designs.

Higher strength of Heat Affected Zone of welded assemblies

Excellent ductility

C28 solution: from a 1 fold only to a fully

crushable performance with high

resistance

C28 solution: from a 1 fold only to a fully

crushable performance with high

resistance

Microstructurally Engineered 6xxx with YS > 280MPa

Best crash index of 18 (Average: 15)

where same strength products gave an

initial best crash index of 12 (Average: 9)


RCAR Structure Test - Efficiency CB


9th - 10th June 10

Typicall AL System

• Fmax = 120 kN

• smax = 170mm Intrusion

• Emax,theor. = 120KN x 0,170m = 20.700J = 100%

• E System= 18.200J = 88%

Efficiency-rate = Emax = Fmax x smax

= 100%

Fmax = Defined bycustomer (Max force

of longitudinals)

smax = Defined by customer and its

package


Correlation FEA & Testing

Towing loadcase


Objective of test:

• No major plasticity's

• No damage of car backbone structure

• Towing cycle fulfilled

Objective of Development

• System with maximum stiffness

• No negative impact on all other loadcases

#1 #2 #3 #4 #5 #6 #7 #8 #9 #10 #11 #12 #13 #14 #15

Hardware 0,00 0,00 0,00 0,10 0,10 0,10 0,10 0,10 0,30 0,50 0,50 0,60 0,60 0,70 0,50

FEM 0,06 0,05 0,06 0,12 0,13 0,20 0,27 0,32 0,38 0,61 0,65 0,65 0,62 0,81 0,60

0,00

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Towing Cycles

Towing Loadcase

Correlation FEA & Testing


Benefits:much more mechanical „guidance“

Optimised deformation performance

Optimised load

sustainable

Towing Loadcase

Standard Concepts vs. Constellium Innovation

Standard towing concept:

Towing eye welded into beam

Standard towing concept:

Towing eye welded into beam

Patented Constellium innovation:

Towing eye extruded in CB

Patented Constellium innovation:

Towing eye extruded in CB


Why RCAR Bumper?


9th - 10th JuneAutomotive Engineering Expo 2015 Nürnberg

Bumpers don‘t Bump ! Component Simulation with Trolly

RCAR Bumper Test

10 kph

Central Impact

Defined Barrier height

No damage on BiW Structure

14

Objective : Min.Bumper Beam Mass with optimal Beam depth

Shape Optimization


60826082

HSA6HSA6


RCAR bumper advantages mass / performance HSA6/6082

Option #1:

Potential usable for weight reduction

Intrusion-Performance:

neutral @ 100mm

Weight:

290g (= 12,4%) weight saving through

HSA6


60826082

HSA6HSA6


RCAR bumper advantages mass / performance HSA6/6082

Option #2: Potential usable for

intrusion optimisation without weight-

increase

Intrusion-Performance:

9mm Intrusion optimisation through

HSA6

Weight:

neutral


Innovation CMS-design 3D, overlap -optimisationRCAR-Bumper overlap QT / Barrier

poor constellation!

RCAR-Bumper-overlap QT / Barrier

with 3D-bended QT = optimised constellation!

Solution: 3D-bumper

RCAR bumper design optimisation 3D

Innovation for light weight design


Lightweight StrategyLightweight Potential based on similar functions

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Steel Aluminium Magnesium

CFK quasi isotropic CFK unidirectional

- 20 % - 30 % - 55 %

- 10 + x %

HSA6

Package and Parameter study

Analytical optimisation- 30 %


The right design, with the right material, at the right place for optimised lightweight, performance and costs!

9th - 10th June 19

Requirements, objectives, innovation strategy

CMS design


CMS System:

• Active-CMS

• Semi Active / 100% Active Systems

Crashbox System:

• Crashbox Innovation

• Low & Highspeed

Beam System:

• Springback Beam (Pedestrian optimised 2nd Loadpath Beam)

CMS Beam

• With Integrated PedestrianProtection System (SMIF)

Pedestrian System

• Pedestrian Protection Honeycomb

Component crash & correlation

Full vehicle crash & correlation

Virtual design and simulation to be continued

Mit freundlicher Genehmigung: BMW AG

constellium high strength crash management systems 20150609

Presentations & Public Speaking

high strength alloys

alloy design press quench

process conditions

constellium hsa

alloys focus

range of potential alloys

manufacturing sites

safety systems