Innovation and Globalization as Factors of Success for ...

Innovation and Globalization as Factors of Success for
Automotive Light-Weighting

Craig Parsons
2012 Management Briefing Seminar (MBS)
Traverse City, Michigan USA
August 6, 2012

1

Agenda

 Gestamp - Company Overview
 Light weighting Techniques
 Hot Stamping / Press Hardening

 Process Description
 Market Growth

 Global Support
 Conclusion

2

Corporación Gestamp

Activities • Steel Services Centers
Employees • Automotive Metal Components
• Renewable Energies

• 33.000 employees worldwide

Sales • Group Turnover 2011: $8.5B USD

Facilities • 120 industrial plants in 21 countries

3

Gestamp in the Global Automotive Industry

Gestamp designs and manufactures components and systems for
the automotive industry

Activity • Automotive metal components supplier for OEMs

Employees • 27.000 employees worldwide

Sales • Turnover 2011: $6.2B USD
Facilities
Leadership • 89 industrial plants worldwide
• Launching 9 new plants

• Body-in-White, Chassis and Mechanisms
• Wide range of technologies
• Focus on weight reduction and safety

4

Gestamp’s Global Footprint

8+1

49 12 + 5
9
11 + 3

Gestamp is present in 19 countries supplying the main Automotive
OEMs through its 98 plants (89 active, 9 under construction)

5

Gestamp Capabilities

Gestamp offers its customers a broad product portfolio

6

Wide Range of Technologies Supporting Customer Needs

7

Wide Range of Technologies Supporting Customer Needs cont…

8

Agenda

 Gestamp - Company Overview
 Need for Light Weighting
 Hot stamping / Press Hardening

 Process Description
 Market Growth

 Global Support
 Conclusion

9

Need for Light Weighting

• United States C.A.F.E. (Corporate Average Fuel Economy)
requirement increases to approximately ~ 56 mpg by 2025

– Multiple publications predict increases will come from:

• Powertrain ~ 50%
• Aerodynamic Improvements ~ 10%

• Body and Frame Weight Reductions ~ 40%

10

Materials and Mass Reduction Expectations

Material Material Replaced Mass Reduction %

Magnesium Steel, Cast Iron 60 – 75%
Carbon Fiber Composites Steel 50 – 60
Aluminum Matrix Composites 40 – 60
Aluminum Steel, Cast Iron 40 – 60
Titanium Steel, Cast Iron 40 – 55
Glass Fiber Composites 25 – 35
Alloy Steel
Steel

Advanced High Strength Steels Mild Steel, Carbon Steel 15 – 25

High Strength Steel Mild Steel 10 – 15

Source: US Department of Energy

11

Balancing Cost and Impact of Light Weighting
• How do you balance the cost and impact?

• Ultra lightweight cars could be built tomorrow but who
could afford them?

• Global supply chain capabilities must exist if
technology is to be adapted on worldwide platforms

12

Methods of Light Weighting

Additional Manufacturing Cost $ Hot Stamping allows increased Mass Reduction
over “Traditional” Cold Stamped AHSS

Mass Reduction %

13

High Strength Steels Used in Steel Body Design

Ultimate Tensile
Stress

Resistance 1500 MPa Usibor
1500

M 1400

1200 MPa DP/CP
1200

1000 MPa DP/CP USIBOR Heating Press
800 MPa 1000 Blanks 900°C hardening &
600 MPa quenching
DP / CP
800

DP/FB
600
DP450

Mild steels Usibor
1500
Usibor @900°C

(delivered)

Press Hardening 10 % 20 % 30 % 40 % 50 % Elongation
AHSS cold Stamping
Deformation

14

Why Use Hot Stamping

Shape Hot stamping
optimization
Complex
Stamping shape

HIGH

Hydroforming

MEDIUM

Roll forming Simple
shape
LOW

MILD HSS VHSS UHSS Material
Strength
Common Applications:
• Ultra high strength and consistency in combination with low weight [A-Pillar Outer R/F], [B-Pillar Outer R/F], [B-
• Dimensional accuracy – very good reproducibility and no spring back Pillar Hinge R/F]
• Hardness / toughness – Excellent plastic deformation properties [Windshield Side member], [Roof Side Rail]
• Weldability – very good due to low carbon content [Door Beam]
• Excellent fatigue properties [Rocker Outer R/F], [Sill Rail]
• Very high formability / Forming of complex geometries Front End crossbeam
• High elongation at break
• Material properties not dependent of forming depth Hot Stamping Technologies
• Well suited for crash applications Tailored Blanks solutions (laser and/or
patchworks)
Soft Zone (Tailored Properties)

15

Agenda

 Gestamp - Company Overview
 Need for Light Weighting
 Hot Stamping / Press Hardening

 Process Description
 Market Growth

 Global Support
 Conclusion

16

Hot Stamping / Press Hardening

Hot Stamping technology (also called press-hardening) allows the
possibility to manufacture light, strong parts with complex geometry.
Hot Stamping is ideal for components requiring dimensional accuracy,
high strength, toughness, good weldability, and light weight characteristics.

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Hot Stamping Process

1. Blanking 2. Blank Heating 3. Forming & 4. Post Form
Quenching Operations

Hot Stamping Process:

Special steels are cut into blanks then heated up
in continuous transfer furnace. The blanks are hot
formed and hardened in the tool in a one hit
operation.

Post form operations include (1) shot blasting for
uncoated boron steel, (2) die cutting or laser
cutting for trims and holes, and (3) welding for
joining parts.

18

Hot Stamping Process Video

19

Agenda

 Gestamp - Company Overview
 Need for Light Weighting
 Hot Stamping / Press Hardening

 Process Description
 Market Growth

 Global Support
 Conclusion

20

Typical Applications for Hot Stamping Technology - Complexity +

15
3

6
4

2

1 Side Impact Beams
2 Bumper Beams
3 Cross & Side Members
4 A & B Pillar Reinforcement
5 Roof Bow
6 Underbody platform parts

21

Strong Growth of Hot Stamping Applications

> 50 parts / vehicle!

Cold stamping is increasingly being replaced by Hot stamping

RISK! Tooling production and press line construction could be a
bottle neck for market growth

22

Gestamp Hot Stamping Capacity

Gestamp acquired hot stamping press manufacturer 
 Strategic operation for assuring growth capacity

Gestamp competences: Assuring production capacity
• Press line design part quality
• Press line construction technical requirements

 Increase standardization GESTAMP OFFERS
• Tooling design • High automated lines (high speed)
• In-house tooling capacities • Reduced laser operations (-60%)
• Latest die technology
Advantages in using two basic • Fast line installation < 14 months
types of ultra high performance
lines: 23

used for small
SL and uncertain

volumes

used for
ML medium and

high volumes

Gestamp Product & Technology Strategy – Hot stamping

R&D + Simulation + Tooling Press line Global production experience
Testing capacities production construction Gestamp´s footprint near to
customers

Gestamp covers the whole value chain of the Hot stamping
Technology

Gestamp is prepared for growth in the Hot Stamping market

24

Agenda

 Gestamp - Company Overview
 Need for Light Weighting
 Hot Stamping / Press Hardening

 Process Description
 Market Growth

 Global Support
 Conclusion

25

Gestamp PH Capabilities 2010

Luleå

Mason Bizkaia Stockholm

Detroit Berlin

Puebla Haynrode
Barcelona

Madrid

Total Nº lines Shanghai

23 ww. Kunshan

26

Gestamp PH Capabilities 2012

Stockholm Czech 1 Line

Mason Bizkaia Berlin
Puebla
Haynrode
Barcelona

Madrid

Total Nº lines Shanghai

55 ww. Kunshan

27

Gestamp R&D Engineering Capabilities

Innovation Product Development &
Benchmarking Engineering

Numerical
simulation
Crash / NVH

Numerical simulation
Forming processes

Prototyping Product Testing
For process for Product
validation validation

28

Gestamp R&D / Engineering Centers

29

Understanding Global Standards

30

Agenda

 Gestamp - Company Overview
 Need for Light Weighting
 Hot Stamping / Press Hardening

 Process Description
 Market Growth

 Global Support
 Conclusion

31