Press hardening from a global perspective Dr. Martin Skrikerud Vice Chief Technical Officer
AP&T WORLD WIDE SALES AND SERVICE China Czech Republic Denmark Germany Japan Poland Slovakia Sweden United Kingdom USA AGENTS Belgium Brazil CIS Finland Italy Mexico Netherlands Norway South Korea Turkey PRODUCTION Blidsberg, Sweden Brescia, Italy Tranemo, Sweden HEADQUARTERS Tranemo, Sweden
ONE RESPONSIBLE PARTNER Automation Operators Interface Presses Tool Handling Systems Tools Technology Integration Customer Service Project Management Documentation Production Lines Competence in-house >> Modular-based systems >> Follow our customers globally Personal contacts at all levels >> Market leader in defined niches
Press Hardening History Mid19-century the first hot rolled and cold rolled boron steel was developed by Norrbottens Jernverk, Luleå (Today SSAB) 1973 - The press hardening process (HotStamping) was developed by Norrbottens Jernverk 1975 - First R&D Project Volvo Truck and Plannja HardTech 1984 - Saab Automobile AB became the first vehicle manufacturer to use hardened boron steel component (Side impact beam) 1991 First bumper beam (Ford)
The process
Boron Alloyed Steel: 22MnB5 Controlled quenching within the tool TTT-Curve for 22MnB5 Ferrite Heating of single blanks Martensite Perlite Bainite Source: Naderi et al. [2007] Delivery Condition* Perlite/Ferrite * Source: ArcelorMittal Final State* Martensite Source: TU Graz 7
Press Hardening Why? High strength Increase safety Reduce weight No sprinback Products: Side impact beams Front and rear bumpers Floor Tunnels B Pillars Chassis components
Press hardening sample geometries
Door ring Tailor Welded blank 0,9-1,8mm Usibor, Ductibor Part development tailored properties
Part development soft zones
Example soft zone die section Heating elements Isolation plates
MARKET TRENDS
CO2 Emission and Targets
CO 2 Emission and Targets potential 2025 75 12.000 Regulation for 2020 95 4.000 fleet Europe 2010 140 0 CO2 emission potential penalty McKinsey 01/2012
Reduced Weight Material Mix Today Mainly conventional steel (49%) Mainly Body in White Mainly Automotive Our Materials Today Tomorrow Mainly Steel, but UHSS + Steel (49%) plus Aluminum (13%) Materials 2020Plus UHSS 15% Magn. 5% Others 1 19% Magn. 5% Plastics 10% Comp. 3% Others 1 20% Alu 9% Alu 13% Steel 52% UHSS 37% Steel 12%
Safety demands change and get tougher
1 Increased components XC60-11% 50 % of BIW weight 40 ~40% 30 V40-20% 20 10 V70 2000 XC90 2002 V70 2007 XC60 2008 S60 2010 V40 2012 Upper limit Upper limit - 40% The new SPA-platform will have about 40% boron steel parts
Cold formed Vs. Hot Formed, Study by FIAT B-PILLAR CPL MOD. 199 = + B-PILLAR CPL MOD. 312 patchwork
Usage and future needs of Usibor (in addition, there is uncoated and Zn-coated material) Source: Arcelor Mittal
TOOLS FOR PRESS HARDENING
Cooling Channel Development Outlet Fig. A Inlet Cooling channels machined through the die sections. Better flow and easier to control the pressure drop. Technical figures Working pressure approx.7,5 Bar Pressure drop, approx. 1,5 Bar Flow approx. 150 liter / min / cavity
Die steels for different needs Material QRO 90 Divar 1.2344 (H 13 improved) Impax (P20 modified) Treatment PVD coating plasma nitrating Die parts in sections maintenance manufacturing
Customer case Panel Dash study
Customer case Panel Dash study Challenges Cracks Panel Dash part Wrinkles
Customer case Panel Dash study Panel Dash evaluation Due to friction in the die the parts crack Crack due to friction small cracks and wrinkles
Solution Surface coating Die clearance Blank shape Customer case Panel Dash study
Customer case Panel Dash study Wrinkles
Customer case Panel Dash study Solution Added grooves Blank shape Thickening 14 %
Sample panel dash: Cooling simulation of the dies 3D tools with cooling channels Tool temperature at the end of quenching
Production panel dash
Process optimization Cooling cycle in die 12-15 s reduced to 4-8 s Die material Increased lifetime and better cooling ratios Handling parts From robot to linear systems Nr. of parts in die 2 to 4 to 6 to 8 / stroke Maintenance cost Multi layer furnace Space savings Possible to use existing buildings -50% space needed Solution Provider From press supplier to provider of production systems
Reference samples within Automotive Volvo Cars VW FIAT Tier 1 USA
Volvo Cars Ongoing Project 2 press hardening lines 9 sets of dies Cooling system 6 Lasers Training of personnel Extensive know-how transfer
FIAT Scope of Supply 5 complete press hardening lines 4 set of press hardening dies Development of Fiat hot forming tooling standards Training of operators and maintenance personnel 1 year of production support Turn Key supply 4 years of successful production
VW Scope of Supply 3 press hardening lines Training of operators and maintenance personnel ½ year of production support Turn key supply
Scope of Supply 2 press hardening lines 10 set s of dies Engineering support Training of operators and maintenance personnel 1 year of production support Turn key supply Tier 1 Supplier USA
AP&T Today Supply WW supply of 70+ complete hot forming lines WW supply of 60+ hot forming dies Developments and Try-out New production facilities New try out center Dies Materials Tailored properties Furnaces Laser
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