BMW

Group

The Application of
Multiphase Steel
in the Body-in-White

Dr.-Ing. Markus Pfestorf

BMW AG

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BMW

Group

1. Demands on materials
2. Functionality
3. Mechanical data of sheet materials
4. Material grade application
5. Forming
6. Joining
7. Summary and outlook

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Demands on Material
Process and Product

BMW

Group

Forming

Joining

Surface/
Corrosion

Functionality

Formability
Punch force
Forming limit
diagram
Cutting
Cutting forces
Spring back

Spot Welding
Adhesive
Bonding
MIG welding
MIG brazing
Laser welding
Riveting

Class A surface
Adhesive
bonding
Paint adhesion
Contact
corrosion

Ductility during crash

(Rp0,2, Rm, A80, )
Fatigue strength
E-Modulus (stiffness)
Weight (density)
Frequency
attenuation
Acoustics

Process: Press-Shop Body-in-White Paint

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Product

BMW

Group

Functionality
Parameters for Crash Performance
BMW rear, 50 km/h, 40 %
US-FMVSS 301, 80 km/h, 70 %

IIHS low speed, 8 km/h, others,

AZT-front/rear, 15 km/h, 40%
FMVSS 201
FMVSS 208
Roof hitting test
Roll over

EURO-NCAP, 64,4 km/h, 40 %

US-NCAP, 56,3 km/h, 100%
Pole (front), 50 km/h, middle

JAPAN-NCAP, 55 km/h, 90
US-LINCAP, 62 km/h
Pole (side), 29 km/h
IIHS side, 50 km/h

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BMW

Group

Functionality
Crash Testing (BMW 6 series coup)
Data for rear crash
Car weight:
1978 kg
Barrier weight: 1365 kg
Barrier speed:

81,7 km/h

Results:
No impact of fuel tank
No impact in passenger cabin
No brittle fracture of trunk lid

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Functionality
Stiffness

BMW

Group
Torsion

32

Bending

28

26,5

29,8

Hz

26

Hz

29

26
24

1. Bending

1. Torsion

28
24,8
22,8

22

24
22

21,8
20,6

20

E34

E39

E60

E28

E34

E39

E60

(1981) (1988)

(1995)

(2003)

(1981) (1988)

(1995)

(2003)

E28

f~

c
m

Inflated scale

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BMW

Group

Functionality
Stiffness

Bending

Torsion

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Mechanical Data
Sheet Steel

BMW

Group
50
%

deep
drawing steel
Stainless
steel

Elongation at fracture A80

40
IF

35
30

TWIP-steel

phosphorus alloyed steel

Wo
Bake
rk
ha
Hardening
rde
ne
d
TRIP

6xxx
(T4)

25
20

5xxx

15
Micro alloyed

10

CP

6xxx
(T6)

5
0

DP

200

400

MS

600

800

1000

N/mm

Yield strength Rp0,2

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1400

Mechanical Data
Comparison: H400T H420LA

BMW

Group
1200

Yield strength Rp0,2

N
mm

H400T
(TRIP700)

800
600

H420LA
(ZSTE420)

400
200
0
0

0,1

0,2

0,3

Forming rate

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0,4

Mechanical Data
Work and Bake Hardening Effects

BMW

Group

Delivery values
before forming

Forming

Paint oven

Final value of
finished products

Work hardening

Bake hardening

Yield strength Rp0,2

800

N
mm

400

200

H300LA (Micro-alloyed)
H300B (Bake-hardening steel)
H300X (Dual-phase steel)

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(Supplier data)

BMW

Group

Material Grade Application

Increasing Utilization of HS Steels
BMW 3 Series

BMW 7 Series

BMW 5 Series

BMW 3 Series

(SOP 1997)

(SOP 2001)

(SOP 2003)

(SOP 2004)

Percentage of material (body in white incl. hang on parts)

Deep Draw Steels

300-340 N/mm

Plastics

180 N/mm

380-420 N/mm

Others

200 -220 N/mm

500-680 N/mm

AlMg aluminum

260 N/mm

> 900 N/mm

AlSi aluminum

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BMW

Group

Material Grade Application

Detailed Case Study: BMW 3 Series
180 N/mm
19%
Deep drawing steel
19%
Others
1%
>900 N/mm
1%
500-800 N/mm
6%
380-420 N/mm
12%

200 -220 N/mm

11%

260 N/mm
9%

300-340 N/mm
22%

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Steel
Other steel
DC 03/04
DX 54
DX 56
H180B, H180Y
H220B, H220Y
H260B, H260Y, H260LA
H300B, H300LA, H300X
H340LA, H340X
H400T
H420LA
D680C
Docol1000
Plastics/others
Plastics
Others

BMW

Group

Material grade application

Impact load path at the BMW 3 series

Load path for

frontal impact
Deformable front
Rigid passenger
cabin
Load path for
side impact

Multi-phase steel grades

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Material grade application

Benefit of Multiphase steel

BMW

Group

Low strength steel < 180N/mm

200
150
100
50

Weight
saving

26%

45%
69%

42%
55%
31%

32%

Previous 3 series

New 3 series

New 3 series

weight: 284 kg,

functionality 98
(size of new 3 series)

weight: 296 kg,

functionality: 2004

weight: 267 kg,

functionality: 2004

+ 12 kg
0

Averaged min. yield

strength: 294 N/mm

kg
averaged min. yield
strength: 178 N/mm

Weight body in white

300

High strength steel

Multiphase steel

Weight saving by multiphase steel

and high strength steel: 29 kg

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- 17 kg

Forming
Formability

BMW

Group
H420LA (ZStE 420)

Severe risk of cracks

Rp0,2: 420 560 N/mm

A80: > 17%

H400T (TRIP700)

Formable without cracks

Rp0,2: 400 500 N/mm

A80: > 24%

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Forming
Spring Back and Buckling

BMW

Group
Spring back and buckling

Steps to prevent
spring back and buckling
(required increase in package volume)

Opening of the profile

by a certain angle

stiffening
bead

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stiffening
bead

BMW

Group

Forming
Deep Draw Tooling Considerations

Conventional deep drawing tool

Deep drawing tool for TRIP 700

material: GGG70
insert not essential
not hardened interactive surface

inserts essential
CVD coated + hardened inserts
cooling system
increased stiffness

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Joining
Electrode Considerations

BMW

Group

Multiphase steel:

Normal steel:

0 15

5,5 mm

6-7 mm

Multiphase steel:
increase the diameter of
the electrodes
increase the electrode
forces
adaptation of the weldability range

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Joining
Adhesive Spot Welding

BMW

Group

Vibration test with H400T + Z100 (hot dip galvanized)

10000
N
6000

Amplitude

4000
k=4,27

2000

1000
1,0E+04

1,0E+05

1,0E+06

Number of cycles

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1,0E+07