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Lightweight door ring concepts using hot stamped laser
welded blanks
Presenter: Gagan Tandon
ArcelorMittal Tailored Blanks Americas
Co-Author: Ivan Viaux
ArcelorMittal Global R&D Montataire
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Table of contents
1. Introduction
Usibor®1500 Hot Stamped Laser Welded Blanks (HS LWB)
2. Details of Pick-up crash behavior and performances
1. IIHS MDB side impact
2. FMVSS 214 pole side impact – 50th and 5th percentile dummy
3. IIHS roof crush
3. Process validation
4. Design efficiency
5. Conclusions
Journey to 54.5 mpg by 2025 with lighter, stronger cost-effective steel solutions
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1. Introduction • ArcelorMittal Tailored Blanks (AMTB) – Global Supplier of LWB
• Strong increase in demand for Hot Stamped Laser Welded Blanks (HS LWB)
– HS LWB used increasingly to meet crash/safety requirements
– Usibor®1500 HS LWB optimizes cost, weight & performance
– AMTB developed a patented technology to weld Usibor®1500 in Europe
– First to market in North America with 2014 Acura MDX Door Ring
• Helped meet IIHS+ rating
• Technology received coveted PACE award – Process Innovation
• Honda received Pace Award for Innovation Partnership
• Honda’s Usibor®1500 HS LWB Door Ring was showcased in 2013 GDIS
• Usibor®1500 HS LWB technology is a game-changer for body design
• Usibor®1500 HS LWB allows flexibility in design to meet performance on variety
of car and truck designs
• Presentation based on one such study done at ArcelorMittal Global R&D
Acknowledgments: ArcelorMittal Global R&D - Automotive Steel Solutions team
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FEA model used for this study
ArcelorMittal Pick-up Analytical Model
• Public Domain model – meets current crash/safety requirements
• Modified for studies – includes Usibor®1500 HS LWB solutions
• Multiple Usibor®1500 HS LWB Door Ring designs were studied for this architecture
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Considered load cases
IIHS
MDB Side Impact
FMVSS 214
POLE 5th Percentile
Dummy - Side Impact
FMVSS 214
POLE 50th Percentile
Dummy - Side Impact
IIHS
Roof crush
Four of the most severe loadcases in the industry were evaluated
Design currently being evaluated for narrow offset crash
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ArcelorMittal HS LWB door ring concept
Usibor®1500
Usibor®1500
Usibor®1500
Ductibor®500P
1 part instead of 4
One stamping tool One stamping operation No post assembly operations
Hot stamping steel grades
Optimized thickness distribution
Laser weld continuous links (no overlap)
Hot-stamping geometry accuracy
Lightweight concept
Flexible - Material thicknesses, number of welds and their locations can be tuned
Optimize - Allows design to meet the needed technical crash/safety requirements
S-in motion concept introduced in 2010
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Usibor®1500
1.0 mm DP590
1.3 mm DP980
1.3 mm
Usibor®1500 HS LWB solutions:
example 5-seam design Multi-part Design
Body side reinforcement outer design
Usibor®1500
1.1 mm
Usibor®1500
2.0 mm
Usibor®1500
0.9 mm
Usibor®1500
1.1 mm
Usibor®1500
2.0 mm
Usibor®1500
1.2 mm
Usibor® 1500 HS LWB door ring is key enabler for a safety cage design
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Usibor®1500 HS LWB solution Multi-part cold stamped and spot welded design
“T-bone” inner reinforcement design
Usibor®1500
1mm
Usibor®1500 0.9mm
Usibor®1500 1.1mm
DP590
1.4mm
DP590 1.2mm
DP980 1.9mm
HR CP800 2.9mm
New “T-bone” Usibor® 1500 HS LWB design further optimizes cost, weight and performance
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Weight comparison
Proposal
Multi-part design 2-seam HS LWB 3-seam HS LWB 4-seam HS LWB 5-seam HS LWB
DP 590 1.3 mm Usibor®
1500 1.2 mm
Usibor®
1500 1.1 mm
Usibor®
1500 1.0 mm
Usibor®
1500 1.0 mm
Usibor®
1500 1.1 mm
Usibor®
1500 2.0 mm
Usibor®
1500 2.0 mm
Usibor®
1500 1.1 mm
Usibor®
1500 0.9 mm
Usibor®
1500 2.0 mm
Usibor®
1500 1.2 mm
Usibor®
1500 2.0 mm
Usibor®
1500 1.1 mm
DP 980 1.3 mm Usibor®
1500 1.2 mm
Usibor®
1500 2.0 mm
Usibor®
1500 1.2 mm
M door ring 17.30 kg 18.21 kg 15.92 kg 15.62 kg 15.57 kg
M T- Bone 6.90 kg 3.60 kg 3.60 kg 3.60 kg 3.60 kg
M total 24.20 kg 21.81 kg 19.52 kg 19.22 kg 19.17 kg
Weight
savings -
2.39 kg
(9.9 %)
4.68 kg
(19.3 %)
4.98 kg
(20.6 %)
5.03 kg
(20.8 %)
Material
utilization 56% 50% 62% 68% 70%
A
B
C
D
E
A
B
C
D
A
B
C
D
A
B
C
A
B
B
D
E
C
A C
D
B
A B
C
A B
A C
D
B
A
Cold stamped
T Bone +
Hot stamped
T Bone +
Usibor®1500 HS LWB solutions are lighter and allow better material utilization
+ + +
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2. Detailed crash performances
• IIHS MDB side impact • FMVSS 214 pole side impact – 50th Percentile Dummy position • FMVSS 214 pole side impact – 5th Percentile Dummy position • IIHS roof crush
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IIHS moving deformable barrier (MDB) side impact
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Structure behavior
Driver seat centerline Driver seat centerline
Multi-part design Usibor® 1500 5-seams HS LWB
Multi-part and Usibor® 1500 HS LWB solutions have similar behavior - IIHS good rating
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MDB Side Impact B-Pillar intrusions Final B-Pillar intrusions
Y location (mm)
Z
location
(mm)
Location of the points used
to measure intrusions
Inner B-Pillar
Usibor®1500 HS LWB solutions have better side intrusion performance
400
600
800
1000
1200
1400
1600
1800
2000
-1000 -800 -600 -400 -200 0
Initial position
PHS intensive Multi-part baseline
HS 2-seam LWB
HS 3-seam LWB
HS 4-seam LWB
HS 5-seam LWB
400
600
800
1000
1200
1400
1600
1800
2000
-1000 -800 -600 -400 -200 0
Initial position
Multi-part design
HS 2-seams LWB
HS 3-seams LWB
HS 4-seams LWB
HS 5-seams LWB
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Proposal
Multi-part design 2-seam HS LWB 3-seam HS LWB 4-seam HS LWB 5-seam HS LWB
IIHS Criteria GOOD GOOD GOOD GOOD GOOD
B-Pillar to driver seat
centerline distance 197 mm 222 mm 226 mm 223 mm 225 mm
B
D
E
C
A C
D
B
A B
C
A B
A C
D
B
A
IIHS - MDB Side performance overview
Usibor®1500 HS LWB solutions have better performance
All solutions reach IIHS good rating level
100
113 115
113 114
90
95
100
105
110
115
120
Multi-part 2-seam HS LWB 3-seam HS LWB 4-seam HS LWB 5-seam HS LWB
Performances compared with multi-part (%)
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FMVSS 214 – POLE 5th Percentile dummy impact results
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FMVSS 214 - POLE 5th Structure behavior
Driver seat centerline
Multi-part design Usibor®1500 5-seam HS LWB
Driver seat centerline
Multi-part design and Usibor®1500 HS LWB solutions have similar behavior and stay
in the area delimited by the driver seat centerline
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FMVSS 214 - POLE 5th - door intrusions
Multi-part design
Max : 413 mm
2-seam HS LWB 3-seam HS LWB
4-seam HS LWB 5-seam HS LWB
Max : 413 mm Max : 413 mm
Max : 415 mm Max : 414 mm
Intrusion
(mm)
Multi-part design and Usibor®1500 HS LWB solutions have similar performance
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Proposal
Multi-part design 2-seam HS LWB 3-seam HS LWB 4-seam HS LWB 5-seam HS LWB
Door to driver
seat centerline
distance 10 mm 15 mm 12 mm 11 mm 12 mm
B
D
E
C
A C
D
B
A B
C
A B
A C
D
B
A
FMVSS 214 - POLE 5th impact summary
Multi-part and Usibor®1500 HS LWB solutions reach good IIHS level ratings
Usibor®1500 HS LWB solutions have better performances than the multi-part design
100
150
120 110 120
0
50
100
150
200
Multi-part 2-seam HS LWB 3-seam HS LWB 4-seam HS LWB 5-seam HS LWB
Performances compared with multi-part (%)
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FMVSS 214 – POLE 50th Percentile dummy impact results
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FMVSS 214 - POLE 50th impact - behavior
Multi-part design Usibor®1500 5-seam HS LWB
Driver seat centerline Driver seat centerline
Multi-part design and Usibor®1500 HS LWB solution have similar behavior and meet IIHS
good rating
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FMVSS 214 - POLE 50th - door intrusions
Multi-part design
Max : 399 mm
2-seam HS LWB 3-seam HS LWB
4-seam HS LWB 5-seam HS LWB
Max : 390 mm Max : 402 mm
Max : 402 mm Max : 402 mm
Intrusion
(mm)
Multi-part design and Usibor®1500 HS LWB solutions have similar performance
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Proposal
Multi-part design 2-seam HS LWB 3-seam HS LWB 4-seam HS LWB 5-seam HS LWB
Door to driver
seat centerline 35 mm 38 mm 29 mm 28 mm 29 mm
B
D
E
C
A C
D
B
A B
C
A B
A C
D
B
A
FMVSS 214 - POLE 50th impact - summary
Multi-part design and Usibor®1500 HS LWB solutions meet IIHS good level rating
Performances are similar and not as critical as pole 5th test (30mm to center line versus 10mm)
100 109
83 80 83
0
20
40
60
80
100
120
Multi-part 2-seam HS LWB 3-seam HS LWB 4-seam HS LWB 5-seam HS LWB
Performances compared with multi-part (%)
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IIHS – Roof crush results
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IIHS – Roof crush - structure behavior
Multi-part design Usibor®1500 5-seam HS LWB
Multi-part design and Usibor®1500 HS LWB solution have similar behavior
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IIHS – Roof crush force curves
Multi-part and Usibor®1500 HS LWB solutions reach good IIHS level
Usibor®1500 HS LWB solutions have better performances than the multi-part design
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B
D
E
C
A C
D
B
A B
C
A B
A C
D
B
A
IIHS – Roof crush performance summary
Multi-part and Usibor®1500 HS LWB solutions reach good IIHS level ratings
Usibor®1500 HS LWB solutions have better performances than the multi-part design
100
107109 108 109
95
100
105
110
Multi-part 2-seam HS LWB 3-seam HS LWB 4-seam HS LWB 5-seam HS LWB
Performances compared with multi-part (%)
Proposal
Multi-part design 2-seam HS LWB 3-seam HS LWB 4-seam HS LWB 5-seam HS LWB
IIHS criteria GOOD GOOD GOOD GOOD GOOD
Max SWR 4.55 4.85 4.96 4.93 4.95
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3. Process validation
• Forming Validation
• Hot Stamping Validation
• Analytical to Experimental Validation
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Door ring forming overview
5-seam design optimized for hot-
stamping process
Usibor®1500
1.2mm
Usibor®1500
2mm
Usibor®1500
1mm
Usibor®1500
1.1mm
Usibor®1500
0.9mm
Forming assessment overview
No critical
forming issue
Basic hot stamping process feasibility study does not show any critical areas
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Detailed stamping analysis
Deeper feasibility analysis in simulation
Tool manufacturing
Hot stamping trials and tool set-up
Successful scale 1 prototyping
Geometry accuracy
Quenching in base metal
Quenching in weld areas
29
1500 mm
12
50
mm
In depth part hot stamping assessment
Door ring prototypes have been already produced by ArcelorMittal S-in motion C-segment study
Usibor®1500 and Ductibor®500 4-seam HS LWB door ring
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4. Design efficiency
• Material Utilization
• Design Efficiency – North America Data
– Normalized Cost Impact (base=100%)
– Material Utilization (%)
– Opportunity Cost ($/kg)
– Weight Savings (kg)
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Material utilization: 5-seam door ring example
Door ring nesting overview
Gross weight 20.59 kg
Net weight 17.30 kg
Material utilization 84%
B C
A
D
E
B
C
A
D
E
Usibor®1500 HS LWB door ring solutions allow very high material utilization rate
A
B
C
A
B
C
T-Bone nesting overview
Gross weight 6.69 kg
Net weight 5.27 kg
Material utilization 79%
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24.2
21.81
19.5219.22 19.17
18
19
20
21
22
23
24
25
Multi-part 2-seam HS
LWB
3-seam HS
LWB
4-seam HS
LWB
5-seam HS
LWB
100
118
107
104
107
90
100
110
120
Multi-part 2-seam HS
LWB
3-seam HS
LWB
4-seam HS
LWB
5-seam HS
LWB
Design efficiency – North American Data
Usibor®1500 HS LWB door ring solutions allow high weight reduction with low cost increase
Opportunity cost $/Kg vs. multipart
Door ring and T-Bone cost (%)
5650
62
68 70
0
10
20
30
40
50
60
70
80
Multi-part 2-seam HS
LWB
3-seam HS
LWB
4-seam HS
LWB
5-seam HS
LWB
Door ring and T-Bone material utilization (%)
Door ring and T-Bone mass (Kg)
0
2.70
1.98
1.40
1.71
0
1
2
3
Multi-part 2-seam HS
LWB
3-seam HS
LWB
4-seam HS
LWB
5-seam HS
LWB
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5. Conclusions
• Game-changer solution for body design
• Solution summary
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Usibor®1500 HS LWB door ring concepts Game-changer Solution for body design
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Usibor®1500 HS LWB Door Ring concept
• Usibor®1500 Hot stamped LWB door ring solution is a flexible design concept
that enables:
– Big mass savings (up to 21% - 10kg per vehicle)
– Part integration
– Better material utilization
– Better crash performances as multi-part structures
– Low cost increase compared with multi-part design
Thank You
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