Steel Innovations in Hot Stamping

Paul Belanger
Director, Gestamp R&D North America
 Organizational Approach Driving Innovation
R&D Centers
SPAIN
SWEDEN
FRANCE
GERMANY
JAPAN
BRAZIL
US
CHINA
INDIA
 Hot Stamping Innovation History
1974 Objective: Replace cold stamping + batch hardening with forming/quenching
in one tool.
 Hot Stamping Innovation History

FIRST HARDENING LINE FIRST PRODUCTS

Wear resistance
• Cutting knives
• Lawn mower knives
• Shovel blades
 Hot Stamping Innovation History
Collaboration with Luleå
Austenizing
University of Technology
Shotblasting
Blanking 1974-1979
• Process
• Tool
Forming & Quenching • Material
• Joining
Key Attributes
• Formability as mild steel
• UHSS material data after hardening
• Yield strength/density ~ extruded Al
• Tight tolerances
• Good weldability
Hot Stamping Innovation History

1983 First Automotive Product

• SAAB 9000: Side impact

beam, Front & Rear door
 Hot Stamping Innovation History
50% Weight % of BIW possible

EVOLUTION OF PHS IN TERMS OF

TECHNOLOGY AND MATERIAL

PH
1G

PH 1st Gen. [Uncoated]

RR Rails 38 %

FR
28% Rails
18%
B-Pillar Local
Door 9% B-Pillar Tunnel Soft Zone
Beam 5% A-Pillar X-MBR
FR/RR Local
Upper Sill
1% Bumper
 Hot Stamping Innovation History
50% Weight % of BIW possible

EVOLUTION OF PHS IN TERMS OF

TECHNOLOGY AND MATERIAL
PH
PH
1G 2G

PH 2nd Gen. [Corrosion protection]

PH 1st Gen. [Uncoated]

RR Rails 38 %

FR
28% Rails
18%
B-Pillar Local
Door 9% B-Pillar Tunnel Soft Zone
Beam 5% A-Pillar X-MBR
FR/RR Local
Upper Sill
1% Bumper
AlSi
 Hot Stamping Innovation History
50% Weight % of BIW possible

EVOLUTION OF PHS IN TERMS OF

TECHNOLOGY AND MATERIAL
PH
PH 3G
PH
1G 2G

PH 3rd Gen. [Softzone]

PH 2nd Gen. [Corrosion protection]
PH 1st Gen. [Uncoated]

RR Rails 38 %

FR
28% Rails
18%
B-Pillar Local
Door 9% B-Pillar Tunnel Soft Zone
Beam 5% A-Pillar X-MBR
FR/RR Local
Upper Sill
1% Bumper
AlSi
 Hot Stamping Innovation History
50% Weight % of BIW possible

EVOLUTION OF PHS IN TERMS OF

PH
TECHNOLOGY AND MATERIAL 4G
PH
PH 3G
PH
1G 2G

PH 4th Gen. [Laser improved ]

PH 3rd Gen. [Softzone]

PH 2nd Gen. [Corrosion protection]
PH 1st Gen. [Uncoated]

RR Rails 38 %

FR
28% Rails
18%
B-Pillar Local
Door 9% B-Pillar Tunnel Soft Zone
Beam 5% A-Pillar X-MBR
FR/RR Local
Upper Sill
1% Bumper
AlSi
PH PH
4G Process
 Co-development examples
5 Technologies yielding 4 innovation products

PROCESS TECHNOLOGY PRODUCT INNOVATION

1 NEW Zn Hot Stamping NEW extreme BODYSIDE

PROCESS TECHNLOGY PRODUCT INNOVATION

2 Remote Laser Seam Welding

NEW front rail LWT
3 In-Die Soft Zones
NEW rear rail LWT
4 Flex Laser Soft Zones
NEW B Pillar LWT
5 3D Laser Cladding (TPP)
 Co-development examples
5 Technologies yielding 4 innovation products

PROCESS TECHNOLOGY PRODUCT INNOVATION

1 NEW Zn Hot Stamping NEW Zn BODYSIDE

PROCESS TECHNLOGY PRODUCT INNOVATION

2 Remote Laser Seam Welding

NEW Front Rail LWT
3 In-Die Soft Zones
NEW Rear Rail LWT
4 Flex Laser Soft Zones
NEW B Pillar LWT
5 3D Laser Cladding (TPP)
 Process Technology 1: Zn MSHc
ALSI PROCESS EQUIPMENT (direct PHD process)

Hydraulic press
5 SPM
2-4 Blanks/stroke

Blanking Heating Stamping Laser

 Process Technology 1: Zn MSHc
ALSI PROCESS EQUIPMENT (direct PHD process)

Hydraulic press
5 SPM
2-4 Blanks/stroke

Blanking Heating Stamping Laser

Zn PROCESS EQUIPMENT (direct MSHc, Multi-Step Hot Stamping Process*)

Mech. transfer press

910º C Multi-step operation
> 15 SPM
1-4 Blanks/stroke
Modified 22MnB5
Blanking Heating Stamping Shotblast

Technology Innovation Status:

- Zn without Microcracks ( <10µm)
- Steel modified to reduce forming start temp, enable mechanical transfer press
- Production ready ~2017-2018 * Patents Pending
 Process Technology 1: Zn MSHc
Zn MSHc (Multi-Step Hot Stamping Process*) Transfer Press
1.800 Tn
2500x4500mm

OP05 OP10 to OP50

SHOTBLAST

 High speed centering & transfer system (OP05)

o Transfer system

 Press
o Servo transfer
o Cycle time = 15-up SPM
o Blanks per stroke = 1 – 4
o 3,000k S/a

 Tooling
o Max OP = 4 – 5
o Thermostabilized tools

* Patents Pending
 Process Technology 1: Zn MSHc
Zn Multi-Step Hot Stamping Process (MSHc*) Summary

 Base material
 Similar post hot stamped mechanical properties to 22MnB5
 Increased formability vs. 22MnB5 at lower temperatures

 Zn-coating
 Offers cathodic protection
 Capable for direct hot stamping process
 Micro cracks < 10µm

 Hot Stamping process

 High productivity (target cycle time 2-3”)
 Furnace protective atmosphere not required
 Possibility to produce complex parts including negative angles
 Good weldability and savings using LWB (Ablation not required)
 No Laser cutting needed
 Tailored properties also possible!!

* Patents Pending
 Product Innovation 1: New Zn Bodyside
Increasing safety requirements… ... with current multipart concept
…

4 parts
assembly

… leads to TWB PH optimized Door Ring

TWB  Enhanced SOF performance

 Part number reduction
 Simplify Assembly Complexity
1 part  Single stroke
 Cost reduction (no ablation)
TWB TWB  Mass saving
…with Blank optimization
 Process Technology 2: Remote Laser Seam Welding
Technology: Remote Laser Seam Welding
Laser welding: With seam tracking -continuous joint
along an edge or short flange

Benefit: Mass savings (reduced flanges) while

maintaining or improving energy absorption

Application opportunities…
Remote laser weld
 Reduced Flanges …on BIW structural parts

Spotwelding B-Pillar
Front Rails
Laser Welding
Rear Rail
A-Pillar

Rocker
 Process Technology 2: Remote Laser Seam Welding
• B-Pillar inner flange reduction • A-Pillar inner flange reduction
Inner

Remote Laser
welding lines

Outer

Laser
welding
Press hardening Remote
Laser welded tube 
Resistant welding Continuity
 Process Technology 3: In-Die Soft Zones
• Technology: In-die partial hardening
 Tailored properties on hot stamped parts
 Controlled heating/cooling tool technology
 Benefits:
 Optional grades obtained: HT400, HT550
 Application freedom: Geometry and strength
 Wide areas feasibility

 Application opportunities…

A-Pillar

Front Rails

B-Pillar
 Process Technology 3: In-Die Soft Zones
Soft flange on A pillar to improve weld ductility

• Material grade HT400

• Oblique pole crash test on vehicle

Side crash view from upper side

NEW VOLVO XC90 Soft flange

 Process Technology 4: Flex Laser Soft Zones
Technology: HT700 Flex Laser
Obtain tailored properties
Material grades obtained: HT700, HT550, HT400
Narrow areas and complex patterns feasible
Application to low thicknesses [0.8 mm]
Rivet solutions to aluminum structures

Application opportunities…

Front Rails Rear Rail

…as combination with press hardened parts

B-Pillar
A-Pillar
Hinge Pillar HS Wheelhouses
 Process Technology 4: Flex Laser Soft Zones
Innovative use of the technology: Advantages
Increased bending areas energy absorption
 Through higher range material

HT400 HT550 HT700

Loading Capacity Energy abs.

+35% +19% abs.

+18% +37% abs.
 Process Technology 4: Flex Laser Soft Zones
Innovative use of the technology: Advantages
Increased bending areas energy absorption
 Through higher range material…
 … combined with more flexible process
Pattern NOK

1 2 3
Loading Capacity Energy abs.
+14%
+8% +33% abs.
+2% +13% abs.
+9% abs.
 Process Technology 5: 3D Laser Cladding (TPP)
Technology: Tailored Product-Process (TPP)
 Melt powdered metal with a laser
 Put material at the right place for
 Crash
 NVH
 Stiffness management

Structure sustainment (Buckle resistance) Energy absorption

Increase Stiffness
Local Increase
Increase Loading capacity Energy

Bending Moment /
Bending Moment /

Force
Force

Intrusion Intrusion

Applications Applications
 Upper B-Pillar in Side crash  Lower B-Pillar in Side crash
 A-Pillar in frontal SORB crash  A-Pillar in Side Pole crash
 Product Innovation 2: Front Rails
Baseline GESTAMP Current Best in Class GESTAMP Future Best in Class Future Best-In-Class
Cold stamping Press Hardening + SZ Multiband
Press Hardening + SZ Technologies
Multiband & Laser applications
Flex Laser Soft Zone:
Decrease hat thickness
HT700 1,5mm1,1mm
USIBOR+SZ
t. 1,1 mm HT700

USIBOR+SZ
Product Innovation t. 1,1mm

PH + SZ Multiband 3D Laser Cladding -TPP:

 Progressive force  Controlled kinematics with local SZ
increase  Increased stiffness with same
Increase local stiffness/
 Controlled
-11% weight
bendingsaving
mode
geometry buckle resistance
-25% weight saving  Improved failure management

-37% weight saving

Spot Welding  Remote Laser Seam Welding:

• Reduce flanges
• Create continuous joint

Performances improvement
 Product Innovation 3: Rear Rails
Baseline GESTAMP Current Best in Class
Cold stamping
GESTAMP Future Best in Class Future Best-In-Class
DP600 Press Hardened + local SZ “snake” Press Hardened + local SZ Technologies
t. 1,4mm
HT400 “snake” & Laser applications
DP600 DP780 HT700
PHS 1500 + SZ
t. 1,4mm t. 1,2mm t. 1,1mm PHS 1500 PHS 1500 +SZ Flex Laser Soft Zone:
t. 1,0mm t. 0,8 mm Decrease hat thickness
PHS 1500
t. 1,0mm
1.1 mm0.8 mm
DP600
t. 1,4mm HT400
HT700
PHS 1500 +SZ
t. 1,1mm
3D Laser Cladding -TPP:
Product Innovation PHS 1500 -30% weight Reduce patch size due
+SZ saving
PH + Local SZ “snake” design to TPP cladding
t. 0,8mm
 Controlled kinematics with local SZ

-11% weight saving  Controlled kinematics with local SZ

 Increased stiffness with same
geometry
 Improved failure management
Spot Welding  Remote Laser Seam Welding:
• Reduce flanges
• Create continuous joint
 Product Innovation 3: Rear Rails
Co-development success example : Honda Rear rails Full vehicle Rear crash validation
FMVSS301 80km/h
 20% weight saving

 Stability
“Snake Design” Rear Rail - Horizontal bending control  Efficiency
Top view  Repeatability
2
 Complexity
3 1
Side view  Single piece
 Patches not required for mode control/energy absorption
Bottom view 3 1
 Minimal spot weld count & reduce piece cost…
2
 Location, size, and properties of soft zones were developed using CAE

Co-developed by GESTAMP R&D (G-Lab) Published by HONDA R&D America (GDIS Seminar 2015)
 Product Innovation 4: B-Pillar
Baseline
GESTAMP Current Best in Class GESTAMP Future Best in Class
Cold stamping Future
PHS 15000 Mono SZ + PHS Reinforcement
PHS 1500 Mono SZ + PHS reinforcement Best-In-Class
Bending mode: local & Laser applications
Technologies
Product Innovation
Product Innovation
• Flex laser soft
3D Laser -TPP:
flanges Reduce patch
Cellar Design
Concept • Improved failure due to laser
management cladding

HT400 Soft

-14% weight
Zone
-27% weight
saving saving
Flex Laser Soft flanges
Create soft material locally Remote Laser
 Improvement of failure Seam Welding:
management Reduce flanges
3D Laser -TPP
Increase top
stiffness
 Improve part
bending

Performances improvement
 Product Innovation 4: B-Pillar
Co-development success example : AUDI B-Pillar
 weight saving and fixation concept

 Smaller cross sections

 Connection hot formed B Pillar to

aluminum bodyside through hemming

 Soft zones in flanges to join with riveting

 Soft zone in lower B Pillar area to ensure
smooth crash kinematics

 Location, size, and properties of soft

zones were developed using CAE
 Product Innovation Summary
 TPP to increase
HS Wheelhouses
Side Impact Beam stiffness
 HT700 Soft Flanges
 Ultra thin PHS 1500,  Ultra thin PHS 1500
t = 0.8mm t = 0.8mm
 TPP Opportunities (All HT grades
 TPP Opportunities
 RSW Failure available)
 Local Stiffness
Front Rails
 HT700 Soft Zones
 HT700 Soft Flanges
 Ultra thin PHS 1500
t = 0.8mm  HT700 Soft Zone
 TPP Opportunities  TPP to increase stiffnes
 Controlled deformation  Laser Remote Technology
Rear Rails

(All HT grades available)

 RSW Failure
 Improve Stiffness
B-Pillar 1 piece
 HT700 Soft Zone Body side
 HT700 Soft Flanges
 TWB
 TPP
 Cladd
A-Pillar  Laser Remote
 RSW Failure  Ducti
 Improve Stiffness Technology
 HT700 Soft Flanges
 TPP  Deformation area
 Tubular Design with Laser
Remote Technology
 Controlled
deformation

(All HT grades available)

 ThankYOU
THANK you