gf automotive ag lightweight activities at georg … automotive ag lightweight activities at georg...

GF Automotive AG

Lightweight Activities at Georg Fischer

Workshop:

Functional and Innovative Lightweight

Concepts and Materials for HEVs

Lightweight Activities at Georg Fischer | 10/2014 | K. Decking2

Lightweighting

Georg Fischer AG



Georg Fischer

Corporation

Foundation: 1802

Headquarter: Switzerland

124 companies in 32 countries

Listed (Swiss stock exchange)

For over 200 years independent

Employees: 14.000

Sales 2013: CHF 3.8 billion

Georg Fischer AG: Three strong Divisions

GF Piping Systems

GF Automotive

GF Machining Solutions

Facts & Figures


Georg Fischer

Three strong Divisions

40% GF Lightweight Solutions

37% GF Piping Systems

23% GF Machining Solutions

100% = CHF 3,77 billion ~ EUR 3,06 billion

Overview 2014 | 03/2014 | GF Automotive6

Georg Fischer

Piping Systems

Your solutionGF Piping Systems is a leading

supplier of piping systems made of

plastics and metal


Georg Fischer

Automotive

Lighter FutureGF Automotive is a leading global

supplier of iron and light metal cast

components for the automotive

industry and industrial applications.


Georg Fischer

Machining Solutions

Keeping promises GF

Machining Solutions’ electric

discharge, high-speed milling and

laser texturing machines, along with

automation solutions, make it the

world’s leading provider

Main purpose of the foundation is

the financial support of projects

related to the improvement of

access to clean drinkable water

for human beings

Founded in 2002

Over 110 Projects in

over 50 Countries

GF Automotive has injected over

CHF 8 million


Georg Fischer

Clean Water Foundation

GF Automotive


EUR 1.22 Bill.Sales

4 940Employees

9 Production Locations

Passion for your Lighter Future


GF Automotive


GF Automotive

Segments & Products

Iron: 62%

~ 3000 Products ≙ 100 000 000 Parts

Light Metal 38%


GF Automotive

Product Segment – Passenger Cars

Powertrain

Chassis

Body / Structure


GF Automotive

Product Summary – Passenger CarsAverage Production per Year

> 1 300 000

> 9 000 000

> 15 000 000

> 3 700 000

> 450 000

> 1 300 000

Chassis

Axle

Steering

Brake

Subframe

Powertrain

Engine

Transmission

Drive Train

Body / Structure

Interieur

Exterieur


GF Automotive

Product Segment – Comm. Vehicles

Powertrain

Chassis

Frame / Cab

> 1 750 000 > 450 000 > 300 000


GF Automotive

Product Summary – Comm. VehiclesAverage Production per Year

> 2 500 000 > 200 000 > 700 000

Powertrain

Engine

Transmission

Drive Train

Chassis

Axle

Steering

Brake

Frame/ CabStructure-mounting parts


GF Automotive

Product Segment – Industrial Application

Energy & Engine

Industry &

Consumer

Offroad


GF Automotive

Global Locations

Headquarter and

R&D

Schaffhausen

Countries delivered

by GF Lightweight Solutions

LMDC

Werdohl

Altenmarkt

Herzogenburg

Production Site /

Headquarter

LMDC

Suzhou

Iron Casting

Kunshan

Cooperation

Grede

Cooperation

Riken

Sales Office

Sales Office

Yokohama

Seoul

Cooperation

Iron Casting

Mettmann

Singen

Herzogenburg

Leipzig


GF Automotive

Added Value: It does not stop with a casting

Joining

Machining Heat TreatmentCasting

Coating Assembly

Downsizing


GF Automotive

Future Drivers for Lightweighting

CO2 Footprint

E- Mobility

Material Development

Design

GF Automotive

Development Competence


State-of-the-art processes:

From design phase to serial

production

Virtual Development:

The complete

component development

from material selection

to casting process is

simulated, validated and

continuously improved

GF Automotive

Material – Optimal Characteristics


Maximize material

advantages:

GF Automotive´s R&D

Department develops state-of-

the-art alloys and maximizes

the specific characteristics of

iron, aluminum and

magnesium consequently

Material

Des

ign

Process

Va

lid

ati

on

GF Automotive

Design – Ideal Shapes


Using degree of freedom:

Virtual tests, simulations and

analyses shorten

development time and reduce

costs for real test runs. In

addition it is possible to define

dimensions, visualize shapes,

anticipate noise and

vibrations, simulate casting

processes and calculate the

lifetime of components.

Material

Des

ign

Process

Va

lid

ati

on

GF Automotive

Process – Precise Procedures


We know how to cast:

Our knowledge in innovation

and light weight construction

requires a continuous

evolution of proven

procedures. GF Automotive

relies on iron-sandcasting and

aluminum and magenesium

die-casting technologies to

cast products in best shape.

Our engineers will find the

optimal process for every part.Material

Des

ign

Process

Va

lid

ati

on

GF Automotive

Validation – Testing Materials and Parts


Testing functions:

Our conviction, that our

products guarantee the

expected advantages, relies

on our accredited testing

laboratory. By state-of-the-art

testing methods,

GF Automotive validates in-

house and other parts already

during development phase.

Material

Des

ign

Process

Va

lid

ati

on

GF Automotive

Material



GF Automotive

Casting or Carbon Composites?

Repair

Herstellung

Recycling Material Cycle

Lower Energy Consumption

Resistance

Costs

Production

Lighter

Corrosion Resistance

Repair

Recycling

CarbonIron

Aluminum

Magnesium


GF Automotive

Material Comparison

GJS 400-15

GJS 450-10

SiboDur

700-10

Aluminum Magnesium Carbon

Fiber

Tensile

Strength Rm

(N/mm2)

Min. 400-450 Min. 700 277-338 217.5-230 3530-4560

0.2%-Yield

Stress Rp0,2

(N/mm2)

Min. 250-310 Min. 440 142-196 112.5-155 -

Elongation

(%)

Min. 10-15 8-12 3.5-12.5 3.5-10 1.1-1.5

Young’s –

Modulus

(kN/mm2)

175 175 72-77 43-45 230-395

Density

(g/cm3)

7.1 7.1 2.6-2.7 1.8 1.8


GF Automotive

Lightweighting Potential

Source University of Cambridge

Weight Reduction

/wikipedia/commons/a/a2/2kg_Gewicht_freigeschnitten.jpg



GF Automotive

Repair Job

Metal Repair

Carbon Fiber Repair


GF Automotive

Production Chain of Carbon Fiber and Magnesium

Carbon Fiber

Magnesium


Carbon Fiber Production Chain

crackingammoxidation

polymerisationoxidation

carbonisationtake effect stack preform

assembly use

crude oilpropylene

acrylonitrileprecursor

oxidised fibercarbon fiber

carbon fabricspackage

mouldCF part

scrap

recycle

plastics


GF Automotive

Magnesium Production Chain

dolomite

sea water

recycle

meltingelectrolyse

high-pressure casting

machiningassembly

use

finished product

raw magnesium

liquid magnesium

casted product

part


GF Automotive

Manufacturing Climate Balance Sheet

CO2 Emissions


Due to pidgeon

process


GF Automotive

Manufacturing Energy Consumption

Energy Consumption


Energy Consumption

Due to pidgeon

process

36

GF Automotive

Emission over Life-Cycle

Lightweight Activities at Georg Fischer | 10/2014 | K. Decking

Change of Perspective: Break-Even

Source: VW, University of Cambridge

Break Even:

0 km High Strength Steel

90.000 km Aluminum

120.000 km Magnesium

170.000 km Carbon Fibre


GF Automotive

Availability

Carbon fiber:

Uses polyacrylonitrile

Magnesium:

8th abundant element

in earth’s crust


Carbon Fiber Metals

GF Automotive

Recycling

Fully recyclable

Used in new alloys

Used as a mixture in new alloys

Recyclable?

At least downcycling or scrap


GF Automotive

Cost Comparison

Costs per Part (in % of Steel)

Steel

Aluminum

Magnesium

Carbon

100

130

155

570

Source: McKinsey&Company, Magnesium own Research

University of Cambridge

Up to 3 times higher costs for carbon fibre

With new precursors and technological progress improving production

processes, a decrease of almost 30% in the global cost of composites is

expected between now and 2020

Today

Tomorrow


GF Automotive

Lightweighting Potential


Weight Reduction



41

GF Automotive

Substitution of Sheet Metal Constructions

Weight Reduction

Casted aluminum compared to

steel sheet assembly out of 10

parts up to 45% less weight



GF Automotive

Carbon Fiber vs. Aluminum

Source: BMW AG

100% Carbon?

43

GF Automotive


Weight Reduction

Seat frame in casted

Magnesium up to 30% less

weight than metal sheet

assembly



GF Automotive

Carbon Fiber vs. Magnesium

- 30% Weight Reduction compared to

conventional Steel-based Designs

Carbon Fiber Magnesium

- 30% Weight Reduction compared to

conventional Steel-based Designs

Source BASF

45

GF Automotive

Bionic Design

Weight reduction

Iron steering knuckle up to

35% less weight through

bionic design



GF Automotive

High Design Freedom for Castings

Front Steering Knuckle

Carbon

- 40%

Iron

- 35%

++

++

+

-

++

++

Iron / Steel


GF Automotive

Material Strengths and Weaknesses

Costs

Recycling

Energy Consumption

Weight Reduction

Repair

Strength +

+

o

+

+

+

o

o

-

++

+

o

++

--

-

++

--

--

Aluminum Magnesium Carbon


GF Automotive

Material Comparison

Weight per Part

In % of Steel

Costs per Part

In % of Steel

Steel

Aluminum

Magnesium

Carbon

100

60

50

50

Steel

Aluminum

Magnesium

Carbon

100

130

155

570

Source: McKinsey&Company, Magnesium own Research

Production

Recycling Costs

Repair

Material CycleMaterial

Serial Production

Energy Consumption

SustainabilityProcess Reliability

Process Reliability




GF Automotive

Which Material?

Carbon

Aluminum Magnesium

Steel

GF Automotive

Design


(Quelle: Prof. Dr. Claus Mattheck)

Principle


Start

Topological Optimization

CAD

Bionic Design


Bionic Design

-12,5 %

Before

GJS 700

7,2 kg

After

SiboDur® 700

6,3 kg

53

Bionic Design

Weight Reduction

Differential housing in iron

casting up to 15% less

weight than predecessor

through bionic design


54

Substitution of System Parts

Weight Reduction

Crossmember, completely

casted in iron has 17% less

weight than combined

assembly out of steel sheet

and iron


55


Weight Reduction

Inno Door Frame in casted

Aluminum up to 40% less

weight than metal sheet

assembly


Additional LightweightingExamples



Product Samples in Series: Maserati Quattroporte

Inner Door Frame

Alloy: AlMg5Si2Mn

Weight : 4,8 kg (- 40%)

Copyright by Maserati


Product Samples in Series: Porsche Panamera

Cam Cover V6 (1-3 and 4-6)

Alloy: AE 44 / MgAl4RE4

Weight : 1,36 / 1,2 kg (- 44%)

Copyright by Porsche



Oil Separator V6/V8

Alloy: AM50 / MgAl9Zn1

Weight: 0,25 / 0,18 kg (-28%)




Oil Sump V6 2WD

Alloy: AE 44/MgAl4RE4

Weight: 4,6 kg (- 47%)



Engine Front Cover

Alloy: AE 44/MgAl4RE4

Weight: 2,6 kg (- 47%)



Product Samples in Series: Opel Cascada


Copyright by Opel

Convertible Roof Top

Alloy: AM50HP

Weight: 2,2 kg (- 40%)

Anchor points for counter ropes

without processing

Minimum wall thickness 1,2 mm

Product Samples in Series: Smart fortwo

Instrument Panel Crossbar

Alloy: MgAl5Mn

Weight: 2,4 kg


Copyright by Smart

Product Samples in Series: BMW X3

BMW X3

Box Swing Arm

Alloy: MgAl9Zn1 (AZ91)

Weight: 0,8 kg (-35%)


Copyright by BMW

Product Samples in Series: Porsche Macan



Engine Front Cover

Alloy: AE44

Weight: 2,6 kg (- 40%)


E-Mobility – New Applications

E- Mobility: Advantages of Castings

Flexibility

Integration

Design Freedom

Economic Efficiency

Material Characteristics

Part Characteristics

…



Wheel carrier with

integrated planetary gear

Formula Student



Battery Housings

VW E-Golf



Single-Piston

Powertrain Applications

Audi A1 e-Tron Prototype


GF Automotive

Lightweigthing – Industrial Applications

Converter Housing

Drum Support


Lightweigthing – Conclusion

Proved solution for lightweigthing? Castings offer…

Broad choice of materials

High design freedom

Large potential for weight savings

High functional integration

Compared to carbon fiber much lower costs and better recyclability


GF Automotive

… for your

Lighter Future

Passion …

ContactKlaus DeckingHead of Marketing, Communication & ServicesBusiness Development New MarketsPhone +41 52 631 21 17Mobile +41 79 633 11 37Fax +41 52 631 28 [email protected]

GF AutomotiveGeorg Fischer Automotive AGAmsler-Laffon-Strasse 98201 SchaffhausenSwitzerlandwww.gfau.com



GF Automotive

Disclaimer

This document is for presentation

purposes only and should not be

construed as an offer, invitation or

solicitation to subscribe for, purchase

or sell any investment. Neither it nor

anything it contains shall form the

basis of any contract whatsoever.

Opinions expressed herein reflect the

current judgement of the management

of Georg Fischer. The presentation

contains forward-looking statements

that involve risks and uncertainties. The

actual results of Georg Fischer may

differ materially from those anticipated

in these forward-looking statements

and forecasts as a result of a number

of factors.

The management of Georg Fischer

does not accept any liability whatsoever

with respect to the use of this

presentation.

Backup



GF Automotive

Lightweighting

Bionic Design

- 32%

Material

Function Integration

- 45%

- 45%


GF Automotive

Product Segment – Passenger Cars

Powertrain

Chassis

Body / Structure


GF Automotive

Product Segment – Comm. Vehicles

Powertrain

Chassis

Frame / Cab


GF Automotive

Product Segment – Industrial Application

Energy & Engine

Industry &

Consumer

Offroad


GF Lightweight Solutions

Rohstoff- und Energieversorgung

Beschaffung und Sicherung von

Rohstoffen und Energie

Rohstoff- und Energierückgewinnung

mit Hilfe moderner Techniken

Einkauf über weltweit agierende

Spezialistenteams

Mehrjahresverträge mit strategischen

Partnern

Virtuelle Beteiligungen bei

Rohstoff- und Energielieferanten


Vergleich von Aluminium und Magnesium

Aluminium Magnesium

Dichte 2,7 g/cm3 1,8 g/cm3

E-Modul 70 GPa 45 GPa

Wärmeleitfähigkeit 238 W/mK 156 W/mK

Wärmeausdehnungskoeffizient 23,5 10-6/K 26,0 10-6/K

Gießbarkeit + ++

Gießtemperatur 710 – 740 °C 670 - 690°C

Wandstärken > 2,0 mm > 1,5 mm

Schutzgas (Brandgefahr) nicht notwendig SO2, (SF6)

Werkzeugstandzeit 100.000 150.000

(Kontakt)-Korrosion + -

Fügetechnologie ++ o

Recyclingfähigkeit ++ +

81

Lightweight Activities at Georg Fischer | 10/2014 | K. Decking Magnesium-Druckguss im Motorenbau 8202/2011

Weitere Merkmale Magnesium / Aluminium

Aluminium Magnesium

Wandstärken > 3,5 > 2,5

Festigkeit + 0

Gießbarkeit + ++

Werkzeugstandzeit 0 ++

Korrosion + -

Kosten + 0

Gewinde + +

Nieten + +

Stanznieten + -

Stanzen + +

Schweissen + -

82


Produkteigenschaften:Magnesium im Vergleich zu Aluminium

Bessere Fliessfähigkeit

dünnwandigere Bauteile möglich (<1,5mm)

geringere Auszugsschrägen möglich

komplexere Bauteile möglich

hohe Oberflächengüte erreichbar

Geringere Toleranzen im Gusszustand erreichbar

Tlws. geringere Nacharbeit notwendig

Tlws. geringere Bearbeitung notwendig, da fertiggegossen

Mg-Legierungen haben starke Neigung zu Kontaktkorossion

Tlws. ist zusätzliche Beschichtung erforderlich

Ggfs. spezielle Fügetechnik erforderlich

83

GF Automotive



State-of-the-art processes:From design phase to serial

production

Virtual Development:The complete component

development from material

selection to casting

process is simulated,

validated and continuously

improved


GF Automotive

Innovation in Material, Design & Process

Process: Core Technology

Design: e.g. Cross Member Design: e.g. Structural Parts

Material: e.g. AluSiDur

High Strength Aluminum Lightweight Crankshafts

Substitution Lightmetal

Principals:

Resources in Nature are limited

Biological mass must be applied

efficiently

Structures in nature aim to

maximal light weight construction

with minimum stress loads


GF Automotive

Bionic Design

After

SiboDur® 700

6,3 kg

Before

GJS 700

7,2 kg


GF Automotive

Bionic Design Examples

- 12,5%

TopologieoptimierungTopologie

Optimierung

Bionic Design

Start Model

Finite

Element

Analyse


GF Automotive


Befor

GJS 400

4,4 kg

After

SiboDur® 700

3,0 kg


GF Automotive


- 32%

90

GF Automotive

Bionic Design

Weight reduction

Differential housing in iron

casting up to 15% less

weight than predecessor

through bionic design


91

GF Automotive

Substitution of System Parts

Weight reduction

Crossmember, completely

casted in iron has 17% less

weight than combined

assembly out of steel sheet

and iron


Source: VW

92

GF Automotive

Emission during Production Process counts


Change of Perspective

GF Automotive



State-of-the-art processes:

From design phase to serial

production

Virtual Development:

The complete

component development

from material selection

to casting process is

simulated, validated and

continuously improved

94

GF Automotive

Substitution of Aluminum through

Magnesium in Powertrain Applications

Weight reduction

Front cover in casted

Magnesium up to 45% less

weight than aluminum


gf automotive ag lightweight activities at georg … automotive ag lightweight activities at georg...

Documents