w w w . a u t o s t e e l .

o r g

Great Designs in Steel is Sponsored by:

AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
Nucor Corporation, Severstal North America and United States Steel Corporation
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The Body in White of the new
BMW 5 Series Gran Turismo.
Duane Copeland
BMW AG
Markus Pfestorf
BMW AG

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 Contents

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 Introduction

Coupe-Like Exterior
- Coupe-Like Silhouette
- Frameless Doors
- High-Quality Appearance of Exterior
Personal Space - (ex. chrome and high gloss black elements)
- Semi Command Position
- Perfect Entry
- Rear Leg Room
- Sedan-like Separated Trunk
- Panoramic Roof

Functionality
- Twin-Trunk Lid
Modern, Elegant Interior - Trunk Volume
- New Type of High-Quality Interior - Flexible 2nd Seat Row / Trunk Size
- Extended Ambient Light
- Single Rear Seat Configuration (option)

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 Relative Product Dimensions

1678 1456 1555

2933 3070 3070

BMW X6
BMW 7 series
BMW 5 series Gran Turismo

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 Technical Components for EficientDynamics

Integral-V-Multilink
Lower CO2 Emissions Suspension

Efficient TwinPower
Turbo Engines

Runflat Tires

Eight Gear Automatic

Transmission with Steptronic

Double-Wishbone Light Weight

Front Axle Body in White Design

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 Torsional Stiffness and Lightweight Coefficient
40.000 4,0

Nm/° 3,5
31,500 cT
3.0
30.000 3,0
2.6 27,500
25.000 2,5

Lightweight coefficient L
20.000 2,0
Torsional stiffness cT

15.000 L L 1,5

10.000 1,0

5.000 0,5

0 0
Closed Roof Sun Roof
L Lightweight Coefficient
mGer Kg mGer. Weight of Body-in-White
L= [ x 10³ ]
CT x A Nm/° x m² cT Torsional Stiffness
A Area (wheel base x track width)

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Increase of Stiffness in the Front and Rear End

High Pressure Cast

Aluminum Shock Tower

Struts Torsion Frame

Aluminum Struts Steel

Aluminum

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 Passive Safety
Driving
Warning
Correction
Crash Unavoidable Post Crash

Active safety Crash Passive safety

Stiffness Strength

cT

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 Load Path of Side Impact

B-Pillar

Impact

Hot Stamped Components

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 USNCAP Barrier

•Passenger Values OK
•Doors Remain Closed

Barrier Weight = 1368 kg

8 Cylinder 4-Wheel Drive

(incl. simulated luggage)
Load = 2555 kg

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 Materials
Steel
DC04
DX54D
DX56D
HC180BD, HC180YD
HC220BD, HC220YD
HC260BD, HC260LAD, HC260X(D)
HC300BD, HC300LAD, HC300X
HC340LAD, HC340X(D)
HC380LAD
HC400T
HC420LAD, HC450X
HC600C, HD680C
HC700X
HC1000W (+TE), HC1000WD+ZF
Aluminium

AlMg3,5Mn
AlMg4,5Mn0,4
AlMg1/AlMg5,7/AlMg1
AlMg0,4Si1,2
AlSi0,6Mg0,5
AlSi10MgMnFe
AlMgSi

Others
Other metallic materials

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 Materials of the Structure
180 MPA 200 – 220 MPa
7% 9%

Deep Drawn Steel 260 MPa

19% 10%

Others
5%
300 - 340 MPa
21%
AlSi Aluminum
2%

1000 MPa
12%

600 - 700 MPa 380 - 450 MPa

1% 14%

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 Weight Savings Compared to Conventional Steel Grades

Hot Stamped Parts: -20,7 kg

Tail Gate: -13,2 kg

Shock Tower: -4,0 kg

Hood: -7 kg
Doors: -16 kg

Total weight savings due to lightweight material design: 60,9 kg

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 Hot Stamped Parts
B-Pillar Reinforcement B-Pillar Reinforcement Inner
Material: HC1000WD+ZF Material: HC1000W
Thickness 1,80 Thickness 1,60
Longitudinal Side Member Inner
A-Pillar Reinforcement Material: HC1000WD+ZF
Material: HC1000W Thickness 1,50
Thickness 1,60
Hinge Carrier Reinforcement
Material: HC1000WD+ZF
Thickness 1,60

Longituidinal Side Member Outer

Material: HC1000WD+ZF
Thickness 1,00

Tunnel Reinforcement
Material: HC1000W+TE Uncoated Material
Thickness: 1,50 Zinc Coated Material

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Press Hardening Process for Zinc Coated Boron Steel

Hot dipped Cold forming Austenizing + Annealing Cleaning Oiling

galvanized coil press hardening (optional) (optional) (optional)

1. Form and Trim in a conventional cold forming process.

2. Heat up the part to Austenitizing Temperature.

3. Pressharden by Quenching in a cooled die.

4. Cleaning of the parts to remove Oxide Layer (optional).

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Press Hardening Process for Zinc coated Boron Steel

Film

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 Press Hardening Process Window
Increase of Oxide Layer

min. Time for Process Window max. Time for

Mechanical • Welding
Properties • Corrosion Protection
(austenitization of the • Paint Adhesion
material) • Glue Adhesion
(Oxide layer and Fe
content)

Oxide Layer
Zn Fe Coating

Basic Material

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 Barrier and Cathodic Protection
A. Overview Picture:
• Zinc Coated Hot Formed
Steel after 10 weeks of
testing

B. Region along the Scratch:

• Cathodic Protection
• No Base Material Corrosion
• Corrosion Creep of Paint:
100µm
0,4mm

Iron Zinc C. Undamaged Region:

• Barrier and Cathodic Protection
Zn Fe Coating

22MnB5 50µm

Conclusion:
• Protection exists even with damaged surface and along cut edges
• Application in wet areas without supplementary support

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 Coating Properties – Zinc Distribution

22MnB5

Zn-Fe-
Layer

10µm 10µm

Zinc-, Iron- Distribution

Conclusion:
• no zinc within the base material
• no Embrittlement of grain
boundaries by zinc
Zn-Fe Layer 22MnB5

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 Other Applications of Zinc Coated Boron Steel

BMW 7 series (SOP 2008) BMW 5 series (SOP 2010)

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 Application of Dual Phase Steel

Steel Grades

HC260XD
HC300X
HC340X(D)
HC400T
HC450X
HC600C, HD680C

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Dachrahmen innen hinten an Serienstand angepasst 14.09.09
 Work Hardening of Dual Phase Steel (HC450X)
Thinning

min. Specimen

max.

Measured Yield
Strength Section 1 Section 2

Bent Part 548 MPa 557 MPa

Deep Drawn Part 767 MPa 580 MPa
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Thank You for Your Attention

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 w w w . a u t o s t e e l . o r g

Great Designs in Steel is Sponsored by:

AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
Nucor Corporation, Severstal North America and United States Steel Corporation
www.autosteel.org