galmus%2016% - lbcg
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- Integrity – Teamwork - Customer Focus – Can-do Attitude – Confidential
GALM US 2016
Ground-breaking design freedom from high strength 7000 series aluminium alloys
- Integrity – Teamwork - Customer Focus – Can-do Attitude – Confidential
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Graham, NC
Swinton, UK (2 locations)
Gerzat, France
Shanghai, China
Calgary, Canada
Ratingen, Germany
Manchester, UK
Worcester, UK
Nottingham, UK
Litvinov, Czech Republic
Tamaqua, PA
Flemington, NJ
Lakehurst, NJ
Niagara Falls, Canada Findlay, OH
Shizuoka, Japan
Madison, IL
Riverside, CA
Brigham City, UT
New Delhi, India
Sydney, Australia
1,900 employees
Luxfer operates 22 plants in 7 countries on four continents with joint ventures and/or distribution centers in four more countries.
USA � Canada � UK � France � Czech Republic � Germany � China � Australia � India � Japan
Cincinnati, OH
Riverhead, NY
Luxfer Group
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Designing for Light-weight vehicle structures
• Materials with high Specific Strength and Stiffness • Minimum material content • Optimised geometry for stability and stress distribution • Acceptable costs and manufacturing capability in the context of the
vehicle programme
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1400 Yield Strength Specific Yield Strength
Mg Al Ti Steel
Yiel
d S
treng
th M
Pa
Spe
cific
Stre
ngth
Strength to weight comparison of structural alloys
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The Superforming process
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Sheet is formed over a heated single surface form tool by controlled air
pressure
“A manufacturing process which uAlises the characterisAcs of certain aluminium alloys to elongate several hundred per cent when subjected to controlled strain rates at a temperature in the range 450 to 500 ºC”
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• Single surface tooling
• Single draw operation, exploiting high elongation available
• Inherent stress relieving and zero strain forming possible
• High formability of material and low flow stress allows complexity and detailing
• Minimal investment is required to compete with cold forming quality
• Multiple parts in one tool
• Low cost tooling
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SRT Viper Fisker Karma
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Application of the process to lightweight BIW • Weight saving achieved by integration of parts, down-
gauging, stiffer geometry, improved packaging from
complex geometry.
• Cost competitiveness from part integration (reduced part
count) and reduced assembly.
• 5xxx alloys for stiffness driven structure
• 7xxx alloys for strength driven structure
5083 Integrated bodyside showing part count rduction
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Superforming developed to form 5xxx alloys • 5083 alloy 145MPa as formed with 25% el. • 5456 alloy 165Mpa with 22% el. • Both alloys achieve over 100% strain during forming • Deep, highly complex parts possible • Circa 10% weight save achievable by moving to 5456 • Numerous chassis applications
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Span of Yield Strength of Aluminium alloy groups
In the foreseeable future 7xxx alloys are likely to offer the ultimate weight saving potential for automotive BIW
Stamping of high strength alloys is challenging • High yield strength means significant elastic
energy and increased spring back • Low elongation to failure gives limited draw • Elevated temperature forming overcomes these
but can significantly reduce mechanical properties
• Forming complex geometry with high strength alloys is highly challenging
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Late 1980’s Harrier GR7 Gun pods made from Al 7475 T5 • 420MPa Ys • Circa 500MPa UTS
Solution heat treatment of skin during Superforming process giving T5 condition panel after artificial age
Aircraft have used Superformed high strength alloys for 40 years
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7xxx T5 condiDon process overview
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7xxx Blank
SoluAon heat treat during Superforming
Process Air quench
ArAficially Age to opAmum properAes
T5 Heat treatment condition defined as: “Cooled from an elevated temperature forming process and then artificially aged”
(Source: ALFED ‘The Properties of Aluminium and its alloys’)
Artificial age process can be optimised to accommodate BIW paint bake and adhesive cure processes
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Al Alloy 7020 composiAon
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Al Si Fe Cu Mn Cr Mg Zn Zr Zr + Ti Other Others Total
7020 Bal 0.35 0.40 0.20 0.050 -‐ 0.50
0.10 -‐ 0.35 1.0-‐1.4 4.0 -‐ 5.0 0.080 -‐
0.20 0.80 -‐ 0.25
0.05 max 0.15 max
Bumper beam extruded from 7020
Al Alloy 7020 is a straightforward first choice for T5 high strength components • Good strength in T5 condition circa 300 MPa Ys, 360 MPa UTS 12% el. • Solutionising temperature compatible with forming process • Good corrosion performance (approved as a marine alloy) • Existing automotive applications • Negligible (or nil) copper content • Weldable (T1 condition circa 260MPa Ys)
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Properties of Superformed 7020 T5
Good ductility allows SPR of 7020 T5
AA7020-‐T5
AA5083-‐O
Accelerated filliform corrosion test pieces showing comparable performance with AA 5083-O
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Approximately 210mm Draw
7020 door forming showing considerable depth of draw achievable in single
Superform tool
Formed 7020 structural component showing complex draw and sharp detail achievable
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Corner of Door Inner panel showing evolution of design from pressed 6xxx to Superformed 7020 T5 • Yield strength up from approx. 220 to 300 MPa • Sharper radii facilitate better packaging and stiffer design • Detailed features reduce the need for additional brackets • Weight save Circa 1.5 Kg per door
Pressed 6xxx T6 Superformed 7020 T5
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Comparative sections through 6xxx and 7020 designs showing high formability of 7020
6xxx blue 7020 green
High formability of 7020 allows high strain geometry and sharp radii with the potential to improve packaging and reduce the need for ancillary brackets and mounts
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In Summary: • The next steps in Aluminium BIW mass reduction are
likely to see increasing use of 7xxx alloys. • 7020 Superformed to T5 heat treated condition can
achieve higher strength than almost all 6xxx alloys with significantly greater formability, facilitating part integration and improved packaging.
• As acceptance of 7xxx alloys for BIW increases, combined with improving surface treatment and paint systems, Copper containing alloys will become acceptable.
• Close to 500 MPa yield is conceivable given suitable alloy and forming process development.
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Thank You
With thanks to Scott Taylor, Tony (AJ) Barnes, Andy Hares and Simon Miller-Jupp