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Erschienen in:

2023 | OriginalPaper | Buchkapitel

7. Prototyping of Multi-material Parts—Efforts to Realize Practical Application of Innovative Materials and Technologies

verfasst von : Koji Chiba

Erschienen in: Innovative Structural Materials

Verlag: Springer Nature Singapore

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Abstract

To confirm the potential for practical application of the innovative materials and innovative joining technologies developed in this project, we examined the performance of the requirements for practical application, such as formability, joining, coating, and rust prevention, through trial production of parts. Specifically, innovative steel sheet was used for the A-pillar, tailored blank fabricated using FSW for the B-pillar outer and inner panels, innovative aluminum for the side member and sill reinforcement member, innovative magnesium for the hood, CFRP/CFRTP panels for the roof, and LFT-D material for the floor, prototypes and evaluations were conducted by applying aluminum and CFRTP dissimilar material joining to the doors. Crash analysis at the actual vehicle level was conducted, and it was confirmed that the performance was equivalent to that of the base vehicle. In summary, the results of the evaluation of the component prototypes indicated that the innovative materials and innovative joining technology have high potential for practical application.

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Vorheriges Kapitel Structural Design

Nächstes Kapitel Recycling and Lifecycle Assessment

Pillar: The pillars are the frame members of an automobile, and run in the vertical direction in the vehicle. A pillar besides the driver is called the A-pillar or front pillar, and the pillar next to it is called the B-pillar or center pillar.

TWB: An abbreviation of Tailor Weld Blank: A blank that is made through welding using a laser or the like with material and thickness combined.

FSW: An abbreviation of Friction Stir Welding: One of solid-phase bonding in which a rotating tool with protrusions is pressed against the joint to induce plastic flow, and bonded together as the tool travels.

Front side member: A member that is located in the front of the vehicle and runs in the front-back direction to support the engine, etc., and serves to absorb the energy generated in a frontal collision.

Side sill: A part that is located at the bottom of the right and left doors and runs in the vehicle’s front-back direction, and serves to absorb the energy generated in a side collision.

Hood: Also called a bonnet, this part is located in the front of the vehicle, and covers the engine room.

Bumper system: A part that is located at the front and rear ends of the vehicle, and absorbs the energy generated in a minor collision. It consists of a beam, and a stay that supports the beam.

Control arm: Being one of the suspension parts, it is a suspension link connected with a hinge between the chassis and an upright suspension or a hub that supports the wheel.

Engine compartment: A region where the engine is installed in the front section of the vehicle.

PHS 1.8 GPa: A hot stamped material with a tensile strength of 1.8GPa.

DP980MPa: Dual Phase Steel: A two-phase steel material made of ferrite and martensite, with a tensile strength of 980 MPa.

Front suspension strut: A body parts that supports the front coil or shock absorber.

DP780MPa: Dual Phase Steel: A tensile strength of 780 MPa.

Undercover: A part that is located on the floor of the body to prevent interference with anything on the road and control the air flow.

Frame: A member that supports the engine and the suspension, and on which the cabin is installed.

FLD: An abbreviation of Forming Limit Diagram. It is a drawing of a press molding with the minimum logarithmic strain and the maximum logarithmic strain at each part being measured, and plotted in a coordinate with the minimum logarithmic strain (\(\varepsilon\) 2) on the horizontal axis and the maximum logarithmic strain (\(\varepsilon\) 1) on the vertical axis.

Spherical stretch forming: A method of checking the height limit below which a plate formed using a spherical punch is not broken.

Full-wrap frontal collision: An experiment in which the vehicle collides with a rigid wall at a velocity of 56 km/h.

Offset collision: An experiment in which the vehicle’s 40% offset part collides with a barrier at a velocity of 64 km/h.

Electrodeposition: Providing rustproof coating by applying electricity in order to apply the coating evenly and uniformly with the aim of preventing the steel sheet from rusting and the coating from peeling off due to flying stones.

JNCAP side collision: Side collision with a moving deformable barrier at a velocity of 55 km/h.

IIHS side collision: Side collision with a moving SUV deformable barrier at a velocity of 50 km/h.

Anisotropy for material: A characteristic in which the material’s property differs between the rolling direction and the vertical direction.

Chemical convertibility: Surface preparation intended to facilitate the adhesion between the metal and the electrodeposition. Formerly, zinc phosphate treatment was the mainstay. But currently, Zr treatment is the mainstay approach.

Pedestrian protection performance: An experiment in which collision between a vehicle and a pedestrian is assumed, and the values of damage to the head and legs of the pedestrian are evaluated.

FSSW: An abbreviation of Friction Stir Spot Welding. A method in which the junction of the workpieces is bonded with frictional heat generated by a rotating tool, and the workpieces are welded together at one spot without having to move the tool.

Pole side collision: Side collision with a static pole at an angle of 90° and a velocity of 32 km/h.

Anisotropy of the yield stress of magnesium: Yield stress during tension and the yield stress during compression differ; in the case of magnesium, the yield stress during compression is smaller.

Titel: Prototyping of Multi-material Parts—Efforts to Realize Practical Application of Innovative Materials and Technologies
verfasst von: Koji Chiba
Verlag: Springer Nature Singapore
Buch: Innovative Structural Materials
Print ISBN: 978-981-9935-21-5

Electronic ISBN: 978-981-9935-22-2

Copyright-Jahr: 2023
DOI: https://doi.org/10.1007/978-981-99-3522-2_7

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