intruck – innovation on road

Innovation on road

Developing the future.

03

04 ThyssenKrupp – Partner to the truck industry 06 InTruck® – Platform for joint development work

Solutions

08 Cab and frame

22 Trailer, chassis and body 30 Powertrain

40 Services

Contents

04

ThyssenKrupp – Partner to the truck industry

Your customers want trucks that are lighter, more powerful, longer lasting, safer and less expensive. We want to help you as a truck manufacturer meet these goals. That’s why we’ve launched InTruck® – to provide you with optimal solutions for cab and frame, trailers, chassis and bodies as well as innovations for the powertrain.

InTruck® brings together the commercial vehicle expertise of the entire ThyssenKrupp Group, from intelligent materials to innovative parts, modules and systems, plus our extensive know-how as a simultaneous engineering partner.

What you rightly expect from us are advanced steels and weight-saving technologies, as well as high-strength, wear-resistant materials capable of withstanding extreme loads. But we also offer intelligent solutions for greater comfort and safety and longer service life, as well as highly efficient powertrain and chassis components that reduce fuel con-sumption and improve vehicle handling.

05

ThyssenKrupp – Partner to the truck industry

07

InTruck® – Platform for joint development work

InTruck® is supported by an interdisciplinary team that harnesses synergies to create energy- and resource-efficient products and services. Through targeted knowledge sharing in joint development projects, we are your fast track to high-tech, low-cost solutions.

InTruck® also gives you access to our materials processing expertise, so you benefit not just from leading-edge materials and components but also from extensive manu-facturing know-how. That’s something many truck manufacturers have already come to appreciate.

Let’s discuss our ideas together and then develop and validate them in your projects: ThyssenKrupp’s capabilities and efficient infrastructures allow comprehensive design analyses, simulations and manufacturing trials to demonstrate feasibility in prototype and short production runs. InTruck® stands for faster development cycles, enhanced functional quality and cost-efficiency, and lower development costs.

❯❯

The following pages show the ThyssenKrupp portfolio for the truck and trailer industry. Product advantages and customer benefits are clearly illustrated – for example in terms of weight, emissions, costs or function, each clearly presented on a separate page. And to go with the key product information, each presentation includes contact details.

Technologies, services, solutions

13

Cab and frame solutions

08 | 09

❯❯

10

Cab and frame

Contact Ralf SünkelThyssenKrupp Steel Europe AG [email protected]

Materials portfolio

Deep-drawing steels

DD, DC, DX

Conventional steels

BHZ Bake hardening steelWHZ Work hardening steelPERFORM® Micro-alloyed steel

Advanced high-strength steels

FB-W® Ferritic-bainitic phase steel RA-K® Retained-austenite steelCP-W®/CP-K® Complex-phase steelDP-W®/DP-K® Dual-phase steelMS-W® Martensitic-phase steelTPN® Three-phase nano steel

Hot-stamping steels

MBW® MBW-W® MBW-K® Manganese-boron steel

Hot and cold-rolled steels Intelligent material solutions for truck applications

��

��

��

��

�

��

�

�

��

��

��

��

��

��

�

��

��

�

�

�

��

��

��

��

�

* as delivered ** hot-stamped

11

Cab and frame

Weight CO2/km Function

ContactRalf SünkelThyssenKrupp Steel Europe AG [email protected]

Costs

LITECOR®

❯❯ Economically attractive lightweight material for drivers’ cabs, cargo space partitions etc.

Highlight

∙ Composite for flat internal and external panels with high weight-reduction potential at attractive costs

Customer benefits

∙ Low-cost weight optimization compared with aluminum

∙ High flexural stiffness and buckling strength

∙ Structure-borne noise damping properties

∙ Grades and thicknesses can be tailored to individual requirements, asymmetric structure possible

LITECOR®

New material class with high weight-reduction potential

Steel face sheet

0.2 to 0.3 mm

Polymer core layer

from approx. 0.3 mm

Steel face sheet

0.2 to 0.3 mm

Reference: Solid aluminum sheet

➜

➜

➜

➜

12


Cab and frame

Costs

➜➜ ➜Weight CO2/km Function

Highlight

∙ Vendor-independent reference truck cab structure for a class N3 vehicle (over 12 tons laden weight) with typical design, costs and structural properties

Main development goals

∙ Focus on structural rigidity and safety require-ments (ECE R29/03) while minimizing weight and costs

∙ Basis for forward-looking concepts using alternative steel grades and steel technologies

Customer benefit

∙ Transparent analyses of the potential of material and technology variants for an objective presentation of their impact on weight, costs, performance etc.

Reference cab

Reference truck cab Objective identification of potential for forward-looking steel concepts

Packaging

neutral neutral neutral neutral

neutral

Corrosion protection

Process compatibility

Other

Performance

Concept

Material

Technology

Design focus

Firewall

Ultrahigh-strength

T3 profiles

Occupant safety with min. weight

A pillar

MBW® 1500

Tailored tempering

Occupant safety with min. weight

Outer skin

LITECOR®

Weight reduction with equivalent performance

Tunnel

BONDAL®

Enhanced comfort, reduced package size

etc.

…

…

…

Forward-looking concepts: Brainstorming and preparation of discussion

13


Cab and frame

Costs

➜ ➜

➜


❯❯ Production-proven tubular design, can be implemented immediately in the vehicle

Highlight

∙ Tube-intensive frame design for lower weight and greater flexibility, e.g. as a basis for cab variants

Customer benefits

∙ Weight optimization through tube-intensive design (increased stiffness of tubes, elimination of unnecessary flanges)

∙ Different cab variants/derivatives can be realized simply

∙ Production processes adapted to different local line configurations – laser welded, spot-weldable modules etc.

∙ High-strength grades in combination with tubular design for maximum weight saving

Tube-intensive design

Roll-formed profiles and hydroforming Tube-intensive design for greater flexibility and lower weight

neutral

Reference: Stamped and welded design

Linear roll-formed profiles

Bent roll-formed profiles

Hydroformed parts

14

ContactHelmut MebusThyssenKrupp Steel Europe AG [email protected]

Costs

Packaging

neutral neutral neutral neutral

neutral➜➜ ➜

Weight

Corrosion protection

CO2/km

Process compatibility

Function

Other

Performance

MaterialKey development goals

∙ Development of a method for the systematic selection of materials by comparing part requirements with material properties

∙ Proven system for car bodies expanded to include truck components such as cab, frame and body

∙ Identification of critical part requirements and suitable steel grades

∙ Inclusion of all cold-rolled, hot-rolled and heavy plate steel grades suitable for use in commercial vehicles

Customer benefits

∙ Systematic material selection “the right material in the right place”

∙ Possibility of lowering costs, reducing weight and enhancing performance

∙ Objective and understandable material recommendation

∙ Early consideration of constraints in the material selection process

Materials concept for commercial vehicles (WeKoKo) Top performance through targeted material selection

Crash: Resistance to deformation

Crash: Energy conversion

Work hardening

Strength

Formability: Stretch forming, deep drawing etc.

Notch impact strength

Formability: Folding, roll forming etc.

Hardness

Acoustics

��

��

Current status

Proposed material

Cab and frame

Cab Frame Body

15

Costs

➜ ➜ ➜ ➜

Weight CO2/km Other


❯❯ For a high degree of design freedom

Highlight

∙ Tailored part properties

Customer benefits

∙ Lower costs Savings on: - Forming dies - Forming processes - Assembly (spot welding) Material utilization greater than 95%

∙ Weight reduction

∙ Part integration

∙ Can be implemented quickly

Applications

∙ Door ring

∙ Side ring

∙ A/B pillars

∙ Firewall

∙ Floor/floor beams

* depending on part

as much as -18%*as much as -20%*

Load-oriented design

Tailored BlanksSteel tailored products

Sheet thicknesses: 0.85–3.00 mm

Cab and frame

16


Cab and frame

Costs

➜ ➜ ➜

➜


❯❯ New technology, not yet in production use; development projects can be realized quickly

Highlight

∙ Shortened process for the production of highly complex tubes and near-net-shape parts on conventional press lines

Customer benefits

∙ Next-generation tubular designs, strong potential for further cost and weight optimization in the vehicle structure

∙ For many parts, significant packaging improvements versus hydroformed parts

∙ Improved material utilization

∙ Use of existing press lines via press adapters

∙ Improved crash performance versus stamped and welded designs, possibility of part integ-ration

T³ profiles for commercial vehicles

T³ technologyInnovative process for the production of tailored tubes

Reference: Hydroforming

17


Cab and frame

Costs

➜ ➜ ➜


❯❯ New strength class for truck production; suitable for immediate production use (MBW® 1500)

Highlight

∙ Ultrahigh-strength grades with tensile strengths up to 1,650 MPa for hot stamping (up to 2,000 MPa in development)

Customer benefits

∙ Significant weight reductions possible

∙ Highly complex part geometries can be realized

∙ Targeted part properties can be achieved via process parameters

∙ Improved crash performance

∙ High dimensional accuracy of parts

∙ Established technology

∙ MBW® available uncoated, hot-dip aluminized or with cathodic corrosion protection

Hot stamping

Manganese-boron steels MBW® for hot stampingWeight reduction for safety-relevant structural parts

neutral

Reference: Cold forming

Tensile strength [MPa]

Elon

gatio

n A

[%

]

MBW® in hot stamping

after press hardening

MBW® as delivered (before heating)

MBW®

1500MBW®

1900

Deep-drawing steels

Conv. high-strength steels

Advanced high-strength steels

MBW® hot forming steels

18

Tailored Tempering: Innovative process for hot stamping Providing tailored properties in monolithic parts


Highlight

∙ Innovative hot stamping process to create parts with varying local mechanical properties

Customer benefits

∙ Significant weight reduction at attractive cost by saving on material, using monolithic designs and reducing the number of parts in the assembly

∙ Excellent crash performance thanks to targeted local high strength combined with high local elongation

∙ Precise reproducibility of part properties

∙ Small hardness transition zones for precision crash design in line with requirements

❯❯ Comprehensive applications advice from ThyssenKrupp Steel Europe’s experts; suitable for immediate production use

Cab and frame

Tailored tempering as used on a B pillar

Costs

➜ ➜

➜


Reference: Tailored blank DP 600, cold forming

neutral

19


Cab and frame

Highlight

∙ Vibration-damping material which effectively reduces structure-borne noise in the frequency ranges typically encountered in vehicles

Customer benefits

∙ Significant reduction in structure-borne noise and good airborne noise insulation

∙ Reduction in weight for secondary acoustic measures (damping pads, insulation materials)

∙ Suitable for spot welding

∙ Good formability in line with the grades used for the face sheets

∙ Suitable for cathodic dip-coating

∙ Applications: Body panels, oil pans, trans-mission covers, brake pad support plates etc.

❯❯ Can be configured to requirements for tailored acoustic solutions; suitable for immediate production use

Oil pan made from BONDAL®

BONDAL®: Sandwich material for optimized acoustics Structure-borne noise damping for body parts, engines, transmissions and brakes

Costs Weight CO2/km Function

Reference: Solid steel sheet with secondary acoustic measures

➜ ➜

➜ ➜

20

TPN®-W 780: Three-Phase with Nano-precipitationHigh-performance material for parts subject to crash stresses


Highlight

∙ Innovative grade with excellent weight- reduction properties: readily formable despite high strength of 800 MPa

Customer benefits

∙ High yield strength and tensile strength coupled with high elongation

∙ Excellent forming behavior permits even complex geometries

∙ High energy absorption for crash loads

∙ Economical weight reduction

∙ Better springback behavior than comparable cold-rolled grades

∙ Available worldwide

❯❯ New material for weight reduction in the production of complex parts; suitable for immediate production use

Cab and frame

Example: Car B pillar

Costs

➜

➜ ➜


HDT780C TPN®-W 780

TPN®-W 780:

greater reserves when

forming complex parts

Reference: Conventional micro-alloyed steel solution

neutral

21

❯❯

24

Lösungen für Trailer und Aufbau

25

Trailer, chassis and bodysolutions

22 | 23

❯❯

24

Trailer, chassis and body

ContactTobias MüllerThyssenKrupp Steel Europe AG [email protected]

Highlights

∙ Reduction in weight and costs through use of high-strength TM-rolled cold forming steels S700MC and S960MC (PERFORM®)

∙ Size range for S700MC extended to 10 mm plate thickness

∙ Development of an ultrahigh-strength steel S960MC

Customer benefits

∙ Good cold forming and processing properties

∙ Higher payloads

∙ Lower weight

∙ Lower costs

S700MC/S960MC (PERFORM®)

Costs

➜ ➜ ➜

Weight CO2/km Other

High-strength and ultrahigh-strength plate (PERFORM®)Lightweight structures for trucks and deck cranes

Red

uctio

n in

pla

te t

hick

ness

rel

ated

to

S35

5 [%

]

Yield strength [MPa] Tension Bending

0

10

20

30

40

50

60

70

80

S355

PERFORM® 500

PERFORM® 600

PERFORM® 700

350 400 450 500 550 600 650 700 750 800

25


Weight-optimized wheels

❯❯ Unused potential for reducing weight of trucks

Highlight

∙ Use of high-strength steels for cost-effective weight reduction of chassis and truck wheels

Customer benefits

∙ Lower weight of chassis/wheels allows higher payloads

∙ Weight-optimized truck wheels reduce unsprung mass

∙ Easier for driver to change wheels

∙ Overall axle-wheel system addressed to maximize functional integration and weight optimization

High-strength and ultrahigh-strength steels for chassis and wheels Less weight – more payload

Costs

➜ ➜


neutral neutral


26


Highlights

∙ Forged lug

∙ Positive connection between tube and base to reduce load on weld

∙ Special welding process to increase lifetime

∙ Banded piston

∙ Piston seal FKM (fluoroelastomer)

∙ Protective sleeve PA6 (polyamide)

Customer benefits

∙ Protective sleeve/piston rod seal: high temperature-resistant

∙ Forged base: high dynamic and static strength

∙ Banded piston: optimum stability of damper characteristics

HD (Heavy Duty) applications (> 6 t)

Trailer damper2-tube technology

Costs Weight Robustness

Reference project: Trailer manufacturer

Other

➜➜

ContactSergio Julio Oliveira ThyssenKrupp Bilstein [email protected]

neutral neutral/lowload-optimized

Piston rod assembly

Protective sleeve

Rod seal Guide Piston valve

Outer tube assembly Bottom valve

27


ContactAxel PohlThyssenKrupp Steel Europe AG [email protected]

PLADUR® TRANSPORT protective overlays – foamed reefers/truck constructional systems (build-ups)

❯❯ PLADUR® TRANSPORT has been successfully used for 10 years by trailer manufacturers

Highlights

∙ Vapor diffusion leak-proof, non-aging and splinter-proof coil coating – coated sheets for reefers

∙ Abrasion and corrosion resistant and weatherproof

∙ High quality visual appearance, easy to clean

Customer benefits

∙ Prepainted sheets, no internal post coating

∙ External coat truck wash capable

∙ Chemical resistance, food safe internal coating

∙ Benefit of steel protective layers compared to alternative materials (e.g. GRP):

- High mechanical loading capability even with thin steel protective layers (0.4–0.6 mm)

- Low heat accumulation capability ➔ faster, energy-saving cooling

- No water absorption ➔ no loss of insulation quality and weight capacity

PLADUR® TRANSPORTOrganic coated sheet for protective overlays of truck-reefers

Costs

➜ ➜ ➜

➜

Weight CO2/km Durability

Compared to reefers with layers of alternative materials

28



Multi-layer build-up

Foil/bond coat

+ covering coat

Backing coat

Pre-treatment

Primer

Highlights

∙ Vapor diffusion leak-proof, non-aging and splinter-proof

∙ High-quality visual appearance

∙ Resistant to abrasion and weathering

Customer benefits

∙ Prepainted sheets, no internal post coating

∙ Available in all colors

∙ Very good formability

∙ Good adherence and suitable for foam application

∙ Paintable

∙ Truck wash capable

PLADUR® TRANSPORT for refrigerated truck trailers PLADUR® E for external cover

Pre-treatment

Hot-dip metal coated substrate

29


Highlights

∙ Vapor diffusion leak-proof, does not decompose

∙ Very good chemical consistency

∙ Certificated physiologically harmless

Customer benefits

∙ Good formability

∙ Good adherence and suitable for foam application

∙ Easy to clean

∙ Good color consistency

∙ No color change on contact with rubber

Two(Double)-layer build-up

PLADUR® TRANSPORT for refrigerated truck trailers PLADUR® HPVC for internal cover

Plastic foil

Backing coat

Pre-treatment

Glue

Pre-treatment

Hot-dip metal coated substrate


Powertrainsolutions

30 | 31

❯❯

32

Baseline Concept

Powertrain

Costs

➜ ➜Weight CO2/km Other

Savings potential depends on project volume and part design

Light, medium and heavy duty applications

Lightweight connecting rodsPart design optimizes weight and load limits

ContactLuis GalliThyssenKrupp Metalúrgica Campo Limpo [email protected]

tbd.

Highlights

∙ Input weight reduction for forging

∙ Weight reduction (lower oscillating masses)

Customer benefits

∙ Weight reduction (5–10%) with unchanged emissions (NOx + CO + PM)

∙ Potential cost advantage

∙ Can be used at over 200 bar

∙ Lower manufacturing complexity for the oil hole lubrication for heavy duty applications

33

Powertrain

Costs Weight CO2/km

➜neutraltbd.

Reliability

Presently it is not possible to provide accurate data on potential savings since this depends on the part in question

Highlights

∙ Direct mounting of piston pin in small end

∙ Diamond Like Carbon (DLC) coated piston pin plus ISEP – “Innovative Surface Engineering Process” on the small end bore

Customer benefits

∙ Improved tribology in the contact zone between piston pin and small end

∙ No bushes required on small end



Bushless connecting rods Direct mounting improves engine reliability


➜

34

Powertrain

Costs

➜ ➜ ➜Weight CO2/km

➜

U-shape bearing

Plasma spray coating

of bearing surface

Robustness

Highlights

∙ Cylindrical main and connecting rod bearings replaced by U-shape bearings

∙ Big-end bearings: coated or non-straight bearings

Customer benefits

∙ Absorbs higher loads from increasing cylinder pressure with no increase in cost

∙ Aids compliance with new emission limits (NOx + CO + PM)

∙ Weight reduction – downsizing effect (e.g. 12% weight reduction with approx. 7% length reduction – based on sports car engine)


Main and connecting rod bearingsCranktrain U-shape concept for downsizing



35

Powertrain

Reference: Camshaft from solid material

Costs

➜ ➜

Weight CO2/km

➜

➜Function

❯❯ Established Presta manufacturing process (press and form fit)

Highlights

∙ The combination of press and form fit of tube and components permits the transmission of high torque

∙ 100% quality data record for every connection

Customer benefits

∙ 40% weight reduction compared to conventional solid truck camshaft

∙ Increased durability thanks to optimized cam material

∙ Cost saving as a result of direct integration of additional functions such as drive wheels

Assembled truck camshaft

Assembled camshaft High torque transmission with signifi cantly lower weight

ContactSebastian HannigThyssenKrupp Presta Ilsenburg [email protected]

36

Powertrain

❯❯ Function- and cost-optimized new manufacturing process

Reference: SOHC with bearing covers

Costs

➜ ➜ ➜Weight CO2/km Function

➜

PICA – Integrated bearing blocks Highlights

∙ Simpler machining and assembly

∙ Reduced bearing friction due to elimination of bearing caps and potential for simplified needle bearing integration

∙ Reduced fuel consumption

Customer benefits

∙ Cost saving

∙ Reduced parts count in cylinder head

∙ Load-matched selection of bearing materials

∙ Increased lifetime

Presta Integrated Camshaft Assembly (PICA) Integrated bearing blocks simplify engine assembly and reduce costs


37

Powertrain

❯❯ Reduced emissions and decreased fuel consumption

Reference: Conventional valve train

Costs

➜ ➜Weight Emissions Function

neutral

Highlights

∙ Type I: Variable phase adjustment of indivi-dual cams on a camshaft (adjustable timing of opening of intake and exhaust valves)

∙ Type II: Variable valve opening times (wider cam lift curve)

Customer benefits

∙ Reduced emissions

∙ Increased torque and power

∙ Compatible with conventional camshafts

Concentric Cam

Concentric Cam Valve train system allows variable phase adjustment and valve opening times


➜

38

Battery Plant TechnologiesTurnkey production and assembly systems for cells, modules and battery packs

ContactHolger GritzkaThyssenKrupp System Engineering GmbH [email protected]

Highlights

∙ Production plants for assembling lithium ion battery cells into battery systems which are used for electric powertrains and in other applications

∙ Test equipment stations for battery modules and battery packs/systems as well as complete electric or hybrid powertrains

Customer benefits

∙ Customer specifications and standards

∙ Adapted health and safety solutions

∙ Required quality assurance

∙ High availability aim

∙ Total cost of ownership (TCO) focus

∙ Production space efficiency yield

❯❯ High competence for automated testing and longstanding experience in assembly systems

Powertrain

Battery Plant Technologies

Consumption

➜ ➜


neutral

Reference: Battery system

TestSystems

Battery Cells

Battery Systems

➜

39

❯❯

30

Lösungen für Fahrwerk und Bremsen

Steel Services for the highest demands

40 | 41

❯❯

42

Services

ThyssenKrupp Stahl-Service-Center Steel Services. Tailor-made.

∙ Hot strip

∙ Cold-rolled sheet

∙ Coated sheet

• hot-dip galvanized/hot-dip aluminized

• electrogalvanized

• organic coated

∙ Stainless steel

∙ Slit strip Thicknesses: 0.3–16 mm

∙ Blanks: rectangular/trapezoidal Thicknesses: 0.4–3.5 mm

∙ Narrow strip center, com-bined and jumbo coiling

∙ Flexible production and tailored finishing

∙ Custom product develop-ment in Group network

∙ Vendor Managed Inventory

∙ Service level agreements

∙ Tailored logistics and IT solutions

∙ Technical customer support and process optimization

Products Processing+ Premium services+

Service highlights

∙ Technical customer support coordinated within the Group – from selection of optimum material through to packaging

∙ Focused range of grades

∙ Implementation of custom solutions for material flatness and corrosion resistance

∙ Customer feedback: State-of-the-art steel technology combined with first-class support on material and processing questions, in service and production

43

Services

ContactChantal EnderThyssenKrupp Stahl-Service-Center GmbH [email protected]

Your advantages at a glance

∙ Premium steel products combined with high-end processing expertise through years of experience

∙ Tailored services to increase value in your supply chain

∙ International presence of our service center group for ideal connections and maximum flexibility

∙ Customer-centric with outstanding range of materials and services

∙ Unique materials and service expertise through combined capabilities of ThyssenKrupp Materials International and ThyssenKrupp Steel Europe

∙ Key-account management with global coverage and multi-material ranges

∙ ISO/TS 16949 and DIN EN ISO 14001 certification

Central contact

ThyssenKrupp AG

ThyssenKrupp Allee 1 · 45143 Essen · Germany

Telephone +49 201 844-0 · Fax +49 201 844-536000

www.thyssenkrupp.com · [email protected]

ThyssenKrupp Steel Europe AG

Kaiser-Wilhelm-Strasse 100 · 47166 Duisburg · Germany

Telephone +49 203 52-0 · Fax +49 203 52-25102

www.thyssenkrupp-steel-europe.com

[email protected]

Participating companies

ThyssenKrupp Steel Europe AG

ThyssenKrupp Presta Ilsenburg GmbH

ThyssenKrupp Metalúrgica Campo Limpo Ltda.

ThyssenKrupp Bilstein GmbH

ThyssenKrupp System Engineering GmbH

ThyssenKrupp Tailored Blanks GmbH

ThyssenKrupp Stahl-Service-Center GmbH

Hoesch Hohenlimburg GmbH

Ord

er n

o. 2

246

∙ Feb

ruar

y 20

13

intruck – innovation on road

Documents