99 0840 Johannes Staeves BMW

Global Automotive Lightweight Materials
24.4.2013, London
Dr. Johannes Staeves
THE RIGHT MATERIAL AT THE RIGHT PLACE.

THE NEED FOR A STRATEGIC REDEFINITION OF THE MATERIAL MIX FOR A
MORE ECONOMICAL AND ECOLOGICAL APPLICATION OF LIGHTWEIGHT
MATERIALS.
CONTENTS.
Global Trends in Automotive Industry.
Challenges for Automotive Lightweight Materials.

• Optimization of Materials
• New Materials
• Hybrid Materials
Multi Material Design.
Conclusions.
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013 Page 2

GLOBAL TRENDS IN AUTOMOTIVE INDUSTRY PUSH THE
DEVELOPMENT OF E-MOBILITY.
Environment Urban Growth Politics

Climate change and subsequent damage More than 60% of the worlds population will live in cities in CO2 – Taxes, Congestion charges
2030
Demand for E-Mobility
Economy Culture Customer Demands

Consumption of resources, costs of fossil fuels Sustainable mobility, social responsibility. Change of moral concepts, demographic trends
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013

NEW DRIVE CONCEPTS REQUIRE NEW LEIGHTWEIGHT
MATERIALS.
EFFICIENT DYNAMICS
Optimisation Hybrid Electric Hydrogen

Further development Intelligent All-electric driving Long-term option
of petrol and diesel combination of and plug-in hybrid for mobility with
engines, innovations electric motor and technology. zero emissions.
for even better fuel combustion engine.
consumption figures.
today
TECHNOLOGICAL SUBSTITUTION.
EACH TECHNOLOGY WILL BE REPLACED.
Basis for success for
tomorrow
strategically critical
Area Basis for today’s
success
Growth,
level of
technologigal
development
Time
Advantage in competition for old Advantage in competition for new
Substitution
technology technology
Product Light sensitivity of film Storage capacity, chip quality
Process Film processing Direct printing, digital devices

Example: digital photography
Quelle: S-Kurven nach C. Marchetti; Beispiele nach F. Malik - „Gezeiten der Großen Transformation 21“, m.om.-Letter 08/10
LINEARE EXTRAPOLATION IS NOT THE RIGHT WAY TO FACE
CHALLENGES. Basis for luccess for
tomorrow
strategically critical
Area
Linear extrapolation:
Growth, Threatening the very
level of existence of firms
lechnologigal
levelopment
Time
Advantage in competition for old Advantage in competition for new
Substitution
technology technology
The most beautiful Clippers …
… just before their displacement by steam boats

EVOLUTION OR REVOLUTION.
Revolution?
Evolution?
Growth,
Level of
Technological
Development
Time
Advantage in Competition for old Advantage in Competition for
Substitution
Technology newTechnology
“I believe in the Future of the Horse. Automobiles will be a temporary occurrence”

[Emperor Wilhelm II. ~ 1900]
"Nuclear powered vacuum cleaners will probably be a reality within 10 years."
[Alex Lewyt, President of the Lewyt Vacuum Cleaner Company]
“640K is Enough For Anyone.” [supposed: Bill Gates 1981]
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013 Quelle: Voest Alpine Magazin 2004
CONTENTS.

• New Materials
Multi Material Constructions.
Conclusions.

CHALLENGES FOR AUTOMOTIVE LIGHTWEIGHT
MATERIALS.
Availability Sustainability Material Restrictions

Grades, Quality and Costs CO2 – footprint, cost effectivness, social responibility End-of-Life Vehicle Directive, REACH.
Challenges for Lightweight Materials
Optimisation of Materials Integration of New Materials Development of Hybrid Materials

Formability, Strength Carbon fiber The right material at the right place

THE RIGHT MATERIAL AT THE RIGHT
PLACE.
CONTENTS.

• New Materials
Conclusions.

OPTIMISATION OF LIGHTWEIGHT MATERIALS.
FORMABILITY.
Perspective
Tomorrow
Today
Yesterday

EACH MATERIAL PROVIDES SPECIFIC ADVANTAGES
AND RESTRICTIONS.
Steel Aluminium Magnesium Carbon Fiber Comp.
duktile HSS UHSS Forging Cast Forging Cast Unidirect. Isotropic
above
Specific Strength 700MPa > Al
Faktor 10
Specific Stiffness
(Tension / Compression)
Buckling, Bending,
Folding
Potentially
Ductility (Crash) A above 40%
TWIP 60%?
Formability / Integral
Construction
Material Costs and Costs Target Material -50%,
Availability Cost Target Process -90%
Creep and Tempera-

ture resistance
Complex Doors, Integral Body Body
Body Geometry
Crash Pillars
Bonnets Components
Interior Interior
Structure Structure
Beams, Advantage
Chassis Wishbones
Beams Connections
Chance for
Suspension shafts Crankcase Crankcase Optimisation?
Restrictions
BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013 Seite 12
THE DEMAND FOR LIGHTWEIGHT DESIGN PUSHES AND
ENABLES MORE COSTLY SOLUTIONS.
HotFormed Steel
Carbon fiber Composites
High strength Steels

Magnesium Sheets
Aluminium Sheets Integral Parts Integral Parts

for Doors, Bonnets and Roofs Tailored Solutions
Cast Aluminium Cast Magnesium

CONTENTS.

• New Materials
Conclusions.

THE EFFORT FOR THE CONVERSION AND THE SYSTEM-DEPENDANT
ADDITIONAL WEIGHT OF THE DRIVE CHAIN CAUSE A SIGNIFICANT
INCREASE IN WEIGHT.
MINI E
System-dependent
additional Weight of the
Electric Drive Chain
MINI Effort for
Cooper Conversion
Weight

LIGHTWEIGHT-APPROACH project i :
THE LIFE-DRIVE CONCEPT WITH ALUMINIUM-CHASSIS AND CFRP- BIW
REVERSES THE SPIRALING TREND OF INCREASING WEIGHT.
No Effort for Conversion
Comparable Car System-dependent Lightweight-Approach: Electric Vehicle

with additional Weight of the LifeDrive Concept MCV
Weight
Combustion Electric Drive Components with Aluminium and CFRP

Engine compensates the additional
Weight of the Electric Drive

INTRODUCTION OF NEW MATERIALS.
ACCESS TO THE COMPLETE PROCESS CHAIN.
Fiber
Precursor Oxidation Surface treatment,
(PAN, spool) carbonisation sizing
Joint Venture
SGL ACF
Textile
Fiber Non-woven fabric
(Spool) Recycling(mat) (reel material)
dry fiber
Preform
Stack production
Trimming of the preform
(Layer structure of Preforming
(Punching)
the component)
BMW
Bauteil
(RTM- Tailoring
Injection of resin Machining
Prozess) (multiple
RTM (CNC / waterjet)
preforms)
Moses Lake, USA Wackersdorf, Germany Landshut/Leipzig, Germany

PRODUCTION OF NON-WOVEN FABRIC.
Wackersdorf, Deutschland

ADAPTION OF MATERIALS TO THE AUTOMOTIOVE
REQUIREMENTS.
3K Fibers 50K Fibers
Woven fabric (Exterieur) Braiding and non-woven fabric (Structure)

CONTENTS.

• New Materials
Conclusions.

HYBRID MATERIALS.
THE COMBINATION OF DIFFERENT MATERIALS ALLOW
FOR NEW MATERIAL PROPERTY PROFILES.
Aluminium-
Aluminium-
Sandwich
Steel- 1+1=3!
Aluminium-
cable rope
Quelle Novelis Aluminium-
Silicium (Alusil)
Corrosion resistance of AlMg1
Quelle Univ. Karlsruhe Aluminium wheel

Strengt of AlMg6
with vermiculie core
Carbon fiber
with copper
d
Ste e l
F
Al u m inium
F
M a g n esium
U
n
i
C a rb on Fibe r Comp.
I
s
Aluminium
CF-
u U o o o
C C d
k H H r r t
a a i
t S S g g r
s s r
i S S i i o
t t e
l n n p
c
e g g i
t
c
.
Sp e cific Stre ngth a b o ve 700M Pa >Al F a ktor 10
Sp e cific Stiff ness (Te sion /

C o m p ressio n)
Bu c kling, Be nding, F olding
D u ctility (Cra sh) A a b o ve 40%

Po te ntially TWI P
60%?
reinforced
F o rm ability / I ntegra l Construction
Strength of carbon fiber

M a te rial Costs and Availabil ity C o sts Target Materia l -50%, Cost Ta rget Process -90%
Creep resistance and weldability of aluminium?

C re e p and Tempera -ture
re sistance
Bo d y C o m p lex Ge ometry C ra sh Pi l la rs D o o rs, Bonn ets I n tegral Components I n terior I n terior Bo d y Structu re Bo d y Structu re
Be a m s, Ad va n tage
C h a ssis Be a m s C o n n ections
Wi sh b o nes
C h a nce for O ptimisa tion?
Su sp ension sh a f ts C ra n kcase C ra n kcase
Re strictions
BM WG ro u p , Dr. Joh annes Staeves, G ALM, 24. 04.2013 Se i te 21

Quelle Fraunhofer IFAM
THE POSSIBILITIES OF HYBRID MATERIALS AND MULTI
MATERIAL DESIGN RANGE FROM THE MATERIAL
STRUCTURE UP TO VEHICLE CONCEPTS.
Hybrid: Composed of different types, of two fold origin, mixed.
As such, it seeks to identify the strengths of different materials, to combine them and to avoid drawbacks.
Hybrid Construction  Material-Mix  Multi Material Design
Vehicle Semi-finished
Module Assembly Component Material
Concept product
Laminated Glass
Live-Drive Aluminium Assembled Aluminium-

concept frontend camshaft magnesium
crankcase Novelis Fusion®
Coatings
Sandwich
Hybrid brake material Material
disk structures
CONTENTS.

• New Materials
Multi Material Constructions  Design.
Conclusions.

MULTI MATERIAL DESIGN.
ALTERNATING INNOVATIONS IN MATERIALS AND
PRODUCTION TECHNOLOGY ENABLE NEW DESIGNS.
Before
1976 Forged
Functionality with
Cast (solid) chill castings one material
1976
4375 g
Sintered cams soldered to tube Separation of

1993 functions
2533 g
2000 Cast (Hollow-Cast) Integration

Outlet 2160 g, Intake 2004 g of functions
2004 Hydroformed Separation of

1351g functions

DIFFERENTIAL DESIGN IS AN ENABLER FOR THE RIGHT
MATERIAL AT THE RIGHT PLACE.
1997 BMW 3 Series Differential
Different steel grades welded design
2001 Mini Integral

Magnesium die-cast design
2004 BMW 3 Series

Differenial
Different steel grades
design
and tailor rolled tube
2007 BMW X5 Integral

Magnesium-die-cast design
2008 BMW M3 - Prototype - Differential

Magnesium sheet welded design

MULTI MATERIAL DESIGN IS A RESULT OF
NETWORKED THINKING AND WORKING.
Incresing customer demands
Legal requirements
Derivates and plattform strategies
Design
Functional
Principles
Multi Material
Lightweight
Construction
Material Production
Constant, reliable and standardised processing properties
Mastering of complex multi material constructions
Short processing Times
Innovative production technologies for new materials
Global availability Global production
Global aaterial atandards Sustainability
Sustainability Capacity utilisation of plants
Multiple suppliers Standardised processes

MULTI MATERIAL CONSTRUCTION.
THE NUMBER OF MULTI MATERIAL JOINTS INCREASES WITH
INCREASING MASTERY OF THESE PROCESSES.
BMW 3 Series
Steel
Conventional Stampings
5 Series (Predecessor) BMW X5,

BMW 7 and BMW 5 Series
Aluminium-Frontend Steel-Aluminium-Design
Rolls Royce Conventional Stampings, Stampings, Hot Formed Steel
Aluminium Profiles and Cast and Cast
Spaceframe
Multiple
No Steel-Aluminium-Joint One Steel-Aluminium Joint
Steel-Aluminium Joints
MULTI MATERIAL CONSTRUCTION.
THE LIFE DRIVE CONCEPT.
BMW i3 Concept BMW i8 Concept
One Aluminium-CFRP-Joint

THE MATERIAL STRATEGY IS TO BE BALANCED WITH
THE STRATEGY FOR THE ARRAY OF PRODUCTS AND
PLANTS.
Klasse Limousine Touring Hatch Coupé Cabrio Roadster SAV SAC
Super
Luxus
upper
upper
middle
middle
compact
small

CONTENTS.

• New Materials
Conclusions.

CONCLUSIONS.
• Driving pleasure, electro mobility and sustainability push lightweight materials and cause a
strong competition. Lightweight activities (minor and major), that could not be used until now
- e.g. due to economical reasons - now become relevant.
• None of the today’s materials can fulfill all requirements of complex automotive structures alone.
• In addition to the substitution of materials a more and more complex multi material design with
hybrid materials will be necessary.
 Competition of materials and simultaneously the cooperation of materials
• The integration of new materials requires a profound knowledge of the interaction between
materials, construction, functions, functional principles, production processes, modular systems
and costs and their dependence on the product portfolio and production volume.
 The right material, the right design and the right production technology at the right place
• Bigger steps in weight reduction with lightweight materials will require new designs and
production concepts including the automotive supply chain.

99 0840 Johannes Staeves BMW

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Global Automotive Lightweight Materials

THE RIGHT MATERIAL AT THE RIGHT PLACE.

Global Trends in Automotive Industry.

Challenges for Automotive Lightweight Materials.

Multi Material Design.

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013 Page 2

Environment Urban Growth Politics

Demand for E-Mobility

Economy Culture Customer Demands

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013

Optimisation Hybrid Electric Hydrogen

Product Light sensitivity of film Storage capacity, chip quality

Process Film processing Direct printing, digital devices

The most beautiful Clippers …

… just before their displacement by steam boats

“I believe in the Future of the Horse. Automobiles will be a temporary occurrence”

Global Trends in Automotive Industry.

Challenges for Automotive Lightweight Materials.

Multi Material Constructions.

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013 Page 8

Availability Sustainability Material Restrictions

Challenges for Lightweight Materials

Optimisation of Materials Integration of New Materials Development of Hybrid Materials

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013

Global Trends in Automotive Industry.

Challenges for Automotive Lightweight Materials.

Multi Material Constructions.

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013 Page 10

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013

duktile HSS UHSS Forging Cast Forging Cast Unidirect. Isotropic

Creep and Tempera-

Carbon fiber Composites

High strength Steels

Aluminium Sheets Integral Parts Integral Parts

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013 Page 13

Global Trends in Automotive Industry.

Challenges for Automotive Lightweight Materials.

Multi Material Constructions.

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013 Page 14

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013

No Effort for Conversion

Comparable Car System-dependent Lightweight-Approach: Electric Vehicle

Combustion Electric Drive Components with Aluminium and CFRP

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013

Moses Lake, USA Wackersdorf, Germany Landshut/Leipzig, Germany

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013

3K Fibers 50K Fibers

Woven fabric (Exterieur) Braiding and non-woven fabric (Structure)

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013

Global Trends in Automotive Industry.

Challenges for Automotive Lightweight Materials.

Multi Material Constructions.

BMW Group, Dr. Johannes Staeves, GALM, 24.04.2013 Page 20

Quelle Univ. Karlsruhe Aluminium wheel

with vermiculie core

Sp e cific Stre ngth a b o ve 700M Pa >Al F a ktor 10

Sp e cific Stiff ness (Te sion /

Bu c kling, Be nding, F olding

D u ctility (Cra sh) A a b o ve 40%

Strength of carbon fiber

Creep resistance and weldability of aluminium?

C h a nce for O ptimisa tion?