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Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts Dr. Sabine Philippe, Dr. Petar Ratchev Bad Nauheim, May 11, 2016

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Page 1: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Dr. Sabine Philippe, Dr. Petar RatchevBad Nauheim, May 11, 2016

Page 2: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Agenda

1. Constellium

2. Drivers and strategy for skin alloy development

3. A new aluminium outer skin sheet product

2A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016

Page 3: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Agenda

1. Constellium

2. Drivers and strategy for skin alloy development

3. A new aluminium outer skin sheet product

3A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016

Page 4: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

An introduction to Constellium 2015

Constellium is a leader in innovative aluminium -based solutions

Over 10,000 full-time employees

€5.2 billion in sales

22 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

2015 key figures

411.05.2016A new aluminium outer skin sheet product for most d emanding car body parts

Page 5: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

� Second largest-volume, fully integrated rolling mill in Europe

� World-class recycling center

� Integrated hot/cold-rolling line

� Joint venture with UACJ (Japan), majority owned by Constellium

NEUF-BRISACH, F SINGEN, D

Bowling Green , KY, US (under construction)

Expanding our automotive body sheet capacity

5A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016

Page 6: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Our auto body sheet portfolio with increasing performance

6

Strongalex®Ultralex®

Securalex®Securalex® HS

Surfalex®Surfalex® HSSurfalex® HF

Formalex®Plus

Strength/Mech.Resistance Crash Design & Style

SurfaceAspect

PRODUCT PERFORMANCE

For replacement of high strength steel parts

and further down gauging

For parts which need energy absorption

For all visible parts

For parts with complex design

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016

Page 7: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Agenda

1. Constellium

2. Drivers and strategy for skin alloy development

3. A new aluminium outer skin sheet product

7A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016

Page 8: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Challenges for skin alloy development

surface quality :orange peel,

roping defects

hemming

corrosion resistance

in-service strength(dent resistance)

deep drawing, stretch forming

sharp lines

In-service performance Ability to form the part

Improving formability, while maintaining a high level of in-service properties

8A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016

edge-cracking

Page 9: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Edge-cracking improvement

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016 9

� Optimized hole geometry:

� Significant improvement by increasing local curvatures in critical areas

� Material optimization:

� Higher elongations lead to higher crack resistance

0

0,1

0,2

0,3

0,4

0,5

5182 6016

Hol

e E

xpan

sion

Rat

io

HE

R =

(D

f-D

0)/D

f

die-cut laser-cut� Cutting quality:

� Significant influence of the cutting process and parameters

� Laser cutting results in higher max. edge strain than press trimming process

old holegeometry

new holegeometry

Page 10: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Formability improvement� Material optimization:

� Higher FLC0 to delay cracks

� Higher work hardening at high strains

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016 10

� Reduced friction:

� To allow material to flow and more homogeneously distributed deformation

� Design optimization:

� The height to radius ratio is important when designing for aluminium

28

32

36

40

44

0,060,080,10,120,140,16

dept

h at

1st

cra

ck (

mm

)

friction coefficient

oil-based drylube

ester-based drylube

red = previous designblue = modified design to solve formability issues

Page 11: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Current design requires sharp character lines

� Sharp character line on the part = small external radius (internal tool radius + ~sheet thickness)

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016 11

� Material optimization:

� Higher work hardening at high strains

� Stretch-bending tests

� We test the alloy ability to form sharp lines on laboratory scale using stretch-bending

� Optical measurement of the outer radius

Page 12: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Development strategy of new aluminium skin alloys

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016 12

0

0,05

0,1

0,15

0,2

0,25

0,3

0,35

0,00 0,10 0,20 0,30

n-va

lue

true strain

current alloy targeted alloy� We use numerical simulation to define the

material needs for real parts. From virtual alloys that allows a given part to be formed we have developed the chemical composition and process route to achieve mechanical properties

� Several traditional target material properties (n5, r10, ∆r, A80, etc) are insufficient indicators of the ability to form real, complex part in 6xxx-series aluminium alloys

� Key development target for us is enhanced work hardening at high strains

Page 13: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Agenda

1. Constellium

2. Drivers and strategy for skin alloy development

3. A new aluminium outer skin sheet product

13A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016

Page 14: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

New aluminium skin alloy: Surfalex® HF

Surfalex® HF gives an improved formability of 10-15% vs. incumbent skin alloys, without compromising any other requirement of outer skins

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016 14

In-service strength(dent resistance)

Corrosion resistance

Roping

Orange peel

Stretch forming & Stretch bending (sharp lines)

Deep drawing

Hemming

Hole expansion

Ability to form the partIn-service performance

Surfalex®

Surfalex® HF

conventional 6016

Page 15: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

New aluminium skin alloy: Surfalex® HF

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016 15

* 2% + 20’@185°C

Si Fe Cu Mn Mg Cr Zn TiSi Fe Cu Mn Mg Cr Zn Ti

1,0 – 1,5 <0,50 <0,20 <0,20 0,25 – 0,60 <0,10 <0,20 <0,15

Ag% A80%Surfalex® 22 25Surfalex® HF 26 29

16

18

20

22

24

26

28

30

elon

gatio

n (%

)

Typical average of Ag and A80 Typical in-service* strength

Rp0.2Surfalex® 210Surfalex® HF 210

50

70

90

110

130

150

170

190

210

230

in-s

ervi

ce s

tren

gth

(MP

a)

� Composition range within AA6016:

� Significant increase of elongations while maintaining the same in-service strength:

Page 16: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

0,18

0,2

0,22

0,24

0,26

0,28

0,3

0,32

0,34

-0,2 -0,1 0 0,1 0,2 0,3 0,4

maj

or s

trai

n

minor strain

Surfalex

SurfalexHF

Optimized for forming of complex parts

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016 16

0,05

0,1

0,15

0,2

0,25

0,3

0,35

0 0,05 0,1 0,15 0,2 0,25

n va

lue

true strain

Surfalex

SurfalexHF

� Higher strain hardening at high strains, for improved stamping and better ability to form sharp “character” lines

� Forming limit curve is improved, particularly in plane strain, enabling the forming of complex and deep parts

Page 17: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

17

Improved formability validated experimentally …� The LDH (Limiting Dome Height) test aims to reproduce press conditions in a simple,

fast laboratory procedure

� This test shows good correlation with plane-strain industrial failures

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016

120 mm

160 mm

0° or 90°

24

25

26

27

28

29

30

Surfalex® Surfalex®HF

Lim

iting

dom

e he

ight

=

hei

ght a

t fai

lure

(m

m)

90°

hemispherical punch + lock beads

sample dimensions

Page 18: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

18

Improved formability validated experimentally…S

urfa

lex

®

Sur

fale

x® H

F

� Constellium in-house stamping trials using difficult door inner tooling

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016

Page 19: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

19

… and numericallyS

urfa

lex

®

Sur

fale

x® H

F

� Surfalex® HF gives clear formability improvement both in simulation and in prototype stamping trials of difficult parts

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016

Page 20: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

2

3

4

5

6

7

10 15 20 25 30

oute

r ra

dii (

mm

)

punch displacement (mm)

Surfalex® -r=1

Surfalex®HF -r=1

Surfalex® -r=2

Surfalex®HF -r=2Surfalex®

/r=1

“Sharper” lines can be achieved

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016 20

� In this stretch-bending test, a high punch displacement is the key indicator of the ability to form sharp lines. The given outer radii values depend on the tool geometry & setup.

� Lower outer radii can be obtained with Surfalex® HF

Interrupted stretch-bending tests at different punch displacements

(up to failure) & opticalmeasurement

Surfalex®HF /r=1

Surfalex®HF /r=2

Surfalex® /r=2Max. punch displacement before

failure is indicated by an arrow

/r=1

/r=1

/r=2

/r=2

Page 21: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Additional relevant forming properties

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016 21

� Surfalex® HF also shows a lower in-plane anisotropy, that means a more similar forming behavior in the 3 directions, and good hemming aptitude

► r-value

153 155

0

20

40

60

80

100

120

140

160

180

Surfalex Surfalex HFbe

ndin

g an

gle

(°)

► bending angle:

0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

Surfalex Surfalex HF

r-va

lue

(8-1

2%)

0° 45° 90°

Page 22: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Perfect surface aspect and corrosion resistance complying with skin products

A new aluminium outer skin sheet product for most d emanding car body parts 11.05.2016 22

NOK OK

� Trend towards thinner paints mean less tolerance for surface disturbance and/or roping lines after forming: excellent surface quality of Surfalex® HF

� Good corrosion resistance: IGC results within specifications

� IGC:

4

� roping:Surfalex® HF

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0 100 200 300 400 500

Cum

ulat

ive

dist

ribut

ion

of 2

5 m

easu

rem

ents

Depth of attacks (µm)

Surfalex®

Surfalex®HF

Page 23: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Summary

� Key trend for skin alloy developments = very few design compromises when converting from steel to aluminium.

� High formability is required (more complex and deep parts, sharp lines, …)

� Key forming parameter is strain hardening at high strains

� We now offer a new skin outer alloy: Surfalex® HF with significant improvements vs incumbent Al alloys

� improved stamping of complex parts, including bodysidepanels

� better ability to form sharp “character” lines

� and with no compromise in

� in-service strength

� hemming performance

� surface aspect quality

Page 24: Pushing the limits of formability: A new aluminium outer skin sheet product for most demanding car body parts

Automoti

ve Circl

e International09/05/201624www.constellium.com

�THANK YOU VERY MUCH

�VIELEN DANK FUR IHRE AUFMERKSAMKEIT

�MERCI BEAUCOUP POUR VOTRE ATTENTION