112 1145 Andrea Merulla Ferrari PDF

BIW design - Innovation Department
Direzione Tecnica 1
FERRARI MATERIALS TECHNOLOGY: THE HISTORY
1940-
1940-1960
In the 1940s, ‘50s, and early ‘60s, Ferrari based its car structures on steel frames with
aluminum panels and aluminium body skins, pursuing lightness to achieve vehicle
performance for both race and sports cars.
1960-
1960-1970
In the 1960s and ‘70s, Ferrari included glass-fibre panels and bodywork on both race and
production cars.
1970, 512 S
1975, 308 GTB Direzione Tecnica 2

1980-
1980-1990
During the 1980s, Ferrari produced a number of prototypes to test different material
combinations; several of these technologies were adopted on production cars.
- Composite bonnet.
1984, GTO - Composite cabin bulkhead.
- Aluminium honeycomb chassis panels.
- Composite tub, bulkhead and panels on steel frame.

- Composite bodywork.
1987, F40
- Composite seats.
- Al bodywork on steel spaceframe with FERAN

1992, 456GT joining technology.
- Composite clamshell bonnet.
Direzione Tecnica 3
1990-
1990-2013
In 1996 Ferrari defined that aluminium technology is the best choice for high
Aluminum technology volume production (production rates of more than 2 cars/day).
1996, 360 Modena 2004, F430 2009, 458 Italia
Since 1995, Ferrari has exploited carbon-honeycomb composite technology for a full
Composite technology carbon-composite, open-top chassis tub, with composite bodywork and composite
interior parts.
1995, F50 2002, Ferrari Enzo 2013, LaFerrari
Direzione Tecnica 4
FERRARI MATERIALS TECHNOLOGY: THE PRESENT
Ferrari’s model range: “ Different Ferrari for different Ferraristi”
FF F12berlinetta
12--cylinder
COST EFFECTIVE SOLUTIONS
12
: -20%
2-4 cars/day T ION > 5 cars/day
U C
R ED
H T 458
IG 458 ITALIA
CALIFORNIA WE SPIDER
8-cylinder
> 10 cars/day > 10 cars/day

Versatility Focus - GRAN TURISMO SPORTS CAR – Performance Focus
PRODUCT POSITIONING
IMPROVE STRUCTURAL PERFORMANCE Direzione Tecnica 5

Aluminum technology
C65K T7 air quench

Welding lines
Casting
C611 T5
6082 T6
6005 T6
Extrusion 6260 T6
6063 T6
H0682 T6
6181A T6
Sheet 6082 T6
Bonding and rivets
6022 T6
If you can see the body DNA you will see ... a wide use and combination of alloys and technologies
Direzione Tecnica 6
Composite technology
HY-
HY-KERS weightto power ratio > 1
No impact on vehicle dimensions
-35mm reduction in center of gravity
100% imporvement in response time
+20% longitudinal acceleration
>50%reduction in CO2 emissions
- 20% Weight
+27% Torsional stiffness Vs Ferrari Enzo
+22% Bengding stiffness
Direzione Tecnica 7
Composite technology
MATERIALS:
High tensile-
tensile-strenght carbon fibre T800
Ultra high tensile-
tensile-strenght carbon fibre T1000
High-
High-modulus carbon fibre M46J/UD
Kevlar for high impact and penetration resistance
Direzione Tecnica
Glass fibre in coupling with aluminium 8
2013
Aluminum technology Composite technology
We continue researching composite technology but four open points have to

be improved:
- Daily production rate

- Failure diagnostics and repair criteria
- Recyclability
- Compliance with existing facilities
Direzione Tecnica 9
FERRARI MATERIALS TECHNOLOGY: NEXT FUTURE
Target definition for our future:
60
Today
Weight / foot print area
50
Full potential of the multimaterial approach
40
30
20 HOW CONSTRAIN
10
Know-
Know-how (best practice): Process (compatibility):
- Structure design - Manufacturing: body shop
0
0 - Function
1 integration
2 3 4 5 6 7 8 paint shop
9 10
- Technologies Year - Repair

- Materials - Recycle
Direzione Tecnica 10
In order to meet our target the items where we are working on are:
60 Today

50
40
30
20
10
HOW 0
0 1 2 3 4 5 6 7 8 9 10
Year
Know-
Know-how (best practice): New concepts design Topology optimization
- Structure design
Global opt.
- Function integration
Results interpretation
- Technologies
- Materials
Local opt. Free-size and size optimization
60 Today

50
40
30
20
10
HOW 0
0 1 2 3 4 5 6 7 8 9 10
Year
Know-
Know-how (best practice):
- Structure design New process to produce extrusion variable thickness along the profiles.
Tailored blanks for strenght and NVH issues.
- Technologies
- Materials New gravity casting process to reduce the minimum thk. up to 2.0mm
with core solutions in order to increase the inertia effect.
60 Today

50
40
30
20
10
HOW 0
0 1 2 3 4 5 6 7 8 9 10
Year
Know-
Know-how (best practice): High stiffness materials:
MMC
- Structure design Orthotropic CFRP
- Technologies
- Materials High strenght materials:
6xxx and 7xxx alloys
Al-Li
Isotropic CFRP
Partial implementation of the multimaterial approach

60
Today
50
40
30 Know-
Know-how (best practice)
20
10 Improve existing process New process and architecture
0
0 1 2 3 4 5 6 7 8 9 10
Year
60 Today

50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10
Year
80%
Welding MIG/CMT
20%
NEW CONTSTRAIN
New process:
80%
- Manufacturing: body shop Mecanichal joint
20%
and bonding
paint shop
- Repair
T1
T1<T2
- Recycle
Paint temperature T2
60 Today

50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10
Year
NEW CONTSTRAIN
Std. procedure
New process:
- Manufacturing: body shop
paint shop
- Repair
- Recycle
New procedure for composite material
60 Today

50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10
Year
Termoplastics resin
NEW CONTSTRAIN
New process:
Natural fibers
paint shop New techniques
- Repair
- Recycle Other...
NEED TIME AND INVESTMENT

NEW CONTSTRAIN
New process:
paint shop
- Repair
- Recycle
The increase of complexity in development pushed Ferrari towards a new design

organization:
Together with partners’ know-how
STRUCTURE
DESIGN
LS
IA
ER
AT
NU
M
M
SIM ERICA DESIGN
ULA L
TI O
N S
ALLOY
Ferrari ’s in-house
NS
IO
US
competence
TR
JOIN
ES
G ING TECH
URIN N I QU
E
CT TE
FA CH
ANU NO
M LO
GI
ES
BENCH AND
DYNAMIC TEST
FERRARI MATERIALS TECHNOLOGY: OUR VISION
The future challenge is continuous weight reduction:
Full potential of the multimaterial approach Partial implementation of the multimaterial approach
130
Much higher costs
120
Total Cost
Higher costs
110
100
Costant/lower costs
90
0 10 20 30 40
Next 5 to 10 year Tomorrow Today
Wheight
With our suppliers we have to understand how the market will react in the next future in order to
address the challenge in a cost effective manner
FERRARI MATERIALS TECHNOLOGY: CONCLUSION
The future challenge is continuous weight reduction along with an

increase in structural performance.
We will continue to improve the intensive aluminium technology

on the body structure for medium/high volume production.
With unweldable new alloys and new materials we have to extend

the usage of bonding, riveting and other techniques in BiW .
We will continue to research composite technology covering four

open points:
- Failure diagnostics and repair criteria

- Daily production rate
- Compliance with existing facilities
- Recyclability
FERRARI MATERIALS TECHNOLOGY
THANK YOU VERY MUCH

FOR YOUR ATTENTION

112 1145 Andrea Merulla Ferrari PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

112 1145 Andrea Merulla Ferrari PDF

Uploaded by

Copyright:

Available Formats

BIW design - Innovation Department

1975, 308 GTB Direzione Tecnica 2

- Composite tub, bulkhead and panels on steel frame.

- Al bodywork on steel spaceframe with FERAN

1996, 360 Modena 2004, F430 2009, 458 Italia

Ferrari’s model range: “ Different Ferrari for different Ferraristi”

> 10 cars/day > 10 cars/day

IMPROVE STRUCTURAL PERFORMANCE Direzione Tecnica 5

C65K T7 air quench

Aluminum technology Composite technology

We continue researching composite technology but four open points have to

- Daily production rate

Target definition for our future:

- Technologies Year - Repair

Weight / foot print area

Weight / foot print area

Weight / foot print area

Partial implementation of the multimaterial approach

10 Improve existing process New process and architecture

Weight / foot print area

Weight / foot print area

Weight / foot print area

NEED TIME AND INVESTMENT

The increase of complexity in development pushed Ferrari towards a new design

Together with partners’ know-how

The future challenge is continuous weight reduction:

The future challenge is continuous weight reduction along with an

We will continue to improve the intensive aluminium technology

With unweldable new alloys and new materials we have to extend

We will continue to research composite technology covering four

- Failure diagnostics and repair criteria

THANK YOU VERY MUCH

You might also like