MERIDIAN  LIGHTWEIGHT  TECHNOLOGIES  -­‐  IMPROVING  THE  FUEL  ECONOMY  OF  OUR  AUTOMOBILES  

MAGNESIUM:    SETTING  A  NEW  PARADIGM  IN  MASS  REDUCTION

1.  MAGNESIUM  &  HIGH  PRESSURE  DIECASTING

2.  MAGNESIUM  PRODUCT  IMPLEMENTATION  

3.  TECHNOLOGY  ROADMAP  

1.  ALLOYS 2.  PRODUCT  DESIGN 3.  GALVANIC  CORROSION 4.  COATINGS 5.  FASTENING  /  JOINING 6.  BUSINESS  PROCESS

4.  CHRYSLER  PACIFICA  LIFTGATE  CASE  STUDY

AGENDA  SETTING  A  NEW  PARADIGM  IN  MASS  REDUCTION

8th  most  abundant  element  on  the  planet

MAGNESIUM    

§  Magnesium  is  the  lightest  of  all  metals  with  a  density  of  1.7g/cm3  (106.13lb/R3),  approximately  ⅓  less  than  aluminum.    

§  Magnesium  plays  a  central  part  in  the  manufacture  and  use  of  compeYng  metal,  provides  ducYlity  in  Al    

§   Advantages  of  magnesium  alloy  use:  

§  Be\er  strength  to  weight  raYo  than  aluminum  

§  Can  be  cast  thinner,  faster  and  machined  easier  than  aluminum  

§  Dampens  vibraYons  

§  Provides  ElectromagneYc  interference  reducYon  

§  Full  recyclability  and  ample  availability    

HIGH  PRESSURE  DIECASTING  =  High  Speed  +  High  Volume  ProducWon § Provides  the  most  complex,  highly  integrated  shapes  in  a  single  process  step    §  Fast  cycle  Ymes  are  ideal  for  high  volume  producYon  quanYYes    § Parts  are  durable  and  dimensionally  stable  ,  while  maintain  Yght  tolerances  § Hundreds  of  thousands  of  casYngs  can  be  produced  before  addiYonal  tooling  is  required  

PRODUCT  DEVELOPMENT  TIMELINE  Meridian  has  been  designing  and  manufacturing  magnesium  automoWve  components  for  30  years

Center  Console Header  Bow Front  End  Structures

Engine  Cradle Steering  Armatures

Oil  Pans  (Aluminum)

Li_gates

Transfer  Case Steering  Column  Components

Pedal  Bracket Cross  Car  Beams Seats Front  of  Dash Transmission  Case

2003   2005   2005   2006   2008   2009   2010  

1987   1990   1994   1998   2001   2003  1985  

Targeted  Magnesium  Applica=ons  /  Industry  Timeline  Applica=ons   Kg  Saved   2017   2018   2019   2020   2021   2022  INTERIOR  APPLICATIONS Steering  Armatures .75  kg  Steering  Column  Housings .5  -­‐  1  kg  Pedal  Bracket   2  kg  Cross  Car  Beam 5  kg  Seat  Frames 6-­‐30  kg  

BODY  APPLICATIONS  Front  End  Structure   3  kg  LiRgate  Inner   10  kg  Door  Inner   10-­‐20  kg  ConverYble  Header 1.5  kg  

CHASSIS  APPLICATIONS  Engine  Cradle   9  kg  

POWERTRAIN  APPLICATIONS  Transmission  Case   4  kg  Transfer  Case   3  kg  Engine  CasYngs   3  kg  Internal  Trans.  CasYngs   1.5  kg  Engine  Mount   1  kg  

Cross  Member  (10  kg)  

Underbody    CasYngs  (10  kg)  

Control  Arm    (3  kg)  

Pillar  Structures  (10  kg)  

Shock  Tower  (3  kg)  

Under  Development  (31  kg  saved)  ImplementaYon  Ready  (60-­‐94  kg  saved)   Unassigned  (36  kg  saved)  

Wheels    (10  kg)  

Knuckles    (3  kg)  

Poten=al  Mass  Saved  (127-­‐161  kg)  

Ba\ery  Tray    (10  kg)  

Tailgate  Inner    (5  kg)  

=

TECHNOLOGY  AND  SPECIFICATIONS  ROADMAP    

COATINGS

SpecificaWons

Powder  coat

E-­‐Coat

Paint

FASTENING

SpecificaWons

Bonding  /  Welding

Self  threading  fasteners

Rivets  /  Self  piercing  rivets

ALLOYS

Environment

TesWng  methods

ApplicaWon  soluWon  sets

SpecificaWons

PRODUCT  DESIGN

General  use

ElongaWon

SpecificaWons

High  Temperature COMPLETE  COMPREHENSIONOF  MAGNESIUM

Magnesium  intensive  automoWve  applicaWons

GALVANIC  CORROSION

CasWng  process  limits

Tolerance  capabiliWes

SpecificaWons

Secondary  process’s

BUSINESS  PROCESS

CAE  correlaWon  &  methods

Prototyping  /  ValidaWon

Tier  1  strategy

SpecificaWons

2017 CHRYSLER PACIFICA LIFTGATE

INTRODUCTION  AND  FEATURES  2017  Chrysler  Pacifica  Li_gate

The  Lightweight  liUgate  assembly  consists  of:    

§  Magnesium  alloy  die-­‐cast  inner  structure    

§  Two-­‐piece  aluminum  sheet  upper  and  lower  outers    

§  Aluminum  stamping  wiper  reinforcement      Magnesium  Inner  Savings  provided:  

§  ReducYon  in  pieces  from  7  to  1  

§  ReducYon  in  weight  from  24  lbs.  to  15.1  lbs.  from  

previous  generaYon  

§  Allows  for  total  assembly  weight  reducYon  of  22  lbs.  

–  nearly  a  50%  weight  reducYon.    

MAGNESIUM  ALLOYS  Material  Property  Comparison

ALUMINUM     MAGNESIUM

PROPERTY  356-­‐T6  

SANDCAST   A380   SILAFONT-­‐36   AZ91D   AM60B   AE44   MRI153   MRI230D  

Tensile  Strength  (MPa)   228   324   283    240     225   245   250   245  

Yield  Strength  (MPa)   186   159   138   160       130       142   170   180  

ElongaYon     5.0   3.5   5.0-­‐11.0*    3.0     8.0       10.0   6.0   5.0  

Density  (g/cm3)   2.68   2.74   2.64    1.81     1.80       1.82   1.82   1.82  

ElasYc  Modulus  (Gpa)   69   71   75   45   45   45   45   45  

*requires  heat  treatment    

Non-­‐ferrous,  die  cast  alloys  have  the  range  of  mechanical  properYes  required  for  most  automoYve  applicaYons.  

MAGNESIUM  ALLOYS  AM60B  Performance  CapabiliWes

Simulated  displacement  characteris=cs  of  an  offset  rear  impact  crash  event  tested  on  a  concept  magnesium  prototype  cas=ng  

 

The  liUgate  is  a  key  structural  component  of  the  vehicle    

§  Provides  structure  to  resist  intrusion  and  maintain  occupant  safety  

§  Absorbs  energy  or  can  transfer  loading  §  ElongaYon  (%e)  of  magnesium  cast  alloy  is  sufficient  to  pass  most  severe  crash  tests    

§  Low  strain  rate  sensiYvity  §  Improves  opYmizaYon  opportuniYes  

MAGNESIUM  ALLOYS  Nominal  Wall  Thickness Since  it  is  cast  instead  of  

stamped,  we  are  able  to  develop  variable  

thicknesses  and  use  ribbing  80%  of  the  cast  magnesium  inner  panel  is  at  a  nominal  wall  thickness  of  2.3mm  

PRODUCT  DESIGN  CAE  CorrelaWon  &  Methods  /  SWffness  

CAE  op=miza=on  tools  were  used  during  early  design  due  to  minimize  deflec=on  under  sta=c  loading  with  least  mass:    

§ Minimize  usage  of  material  for  material  addiYons  by  maximizing  the  secYon  of  the  casYng  through  computaYonal  analysis  

 

Two  topology  op=miza=ons  completed:  

1.  Ribbing  pa\ern  that  maximizes  enYre  secYon  

2.  Ribbing  pa\ern  is  designed  to  ensure  fluid  drainage  and  not  to  interfere  with  the  seal  surface  

 

A  number  of  these  op=miza=on  modifica=ons  were  incorporated  into  the  final  design  to:  

§  Improve  NVH  by  over  16Hz  in  bending  from  previous  generaYon  

§  Increase  torsional  sYffness  over  alternaYve  materials  

 

Maximizes  Sec=on  Modulus  

Restric=ons  –  Seal  Surface  /  Fluid  Drainage  

PRODUCT  DESIGN  Packaging

The  liUgate  structure  is  a  key  component  to  package  numerous  components  of  the  vehicle:  

§  Provides  structure  and  packaging  space  for  mechanical  /  electrical  devices,  power  and  signal  distribuYon  

Design  of  liUgate  inner  op=mized  for  magnesium  die-­‐cas=ng:  

§  Speaker  boxes  designed  in  lower  porYon  of  casYng  to  mount  rear  speakers  

§  Local  ribbing  and  thickness  addiYons  allowed  for  design  of  tail  lamp  housing  

§  Tail  lamp  housing  allows  for  access  to  electrical  connecYons  of  the  lamp  through  an  access  panel  and  designed  clearance  holes  in  the  casYng  

Tail-­‐lamp  housing  Speaker  box  

GALVANIC  CORROSION  Hinge  Assembly

§  The  liRgate  inner  is  considered  to  be  in  a  dry  area  of  the  vehicle  ,  the  hinge  assembly  is  the  only  component  where  corrosion  was  a  concern.  

§  Galvanic  corrosion  is  a  concern  when  mag  is  connected  to  another  metal  in  presence  of  an  electrolyte  

§  Contact  far  bigger  issue  than  surface  corrosion  

§  An  aluminum  isolator  was  inserted  between  the  magnesium  casYng  and  the  steel  stamping.  

 

HINGE  DESIGN    

Reduced  joining  technologies  from  84  to  10

• Mass  reduc=on  • Part  reduc=on  • Joining  reduc=on  

PREVIOUS  GENERATION  

CURRENT  GENERATION  

FASTENING,  JOINING  &  ASSEMBLY  

§ Magnesium  casYng  inner  

§  Aluminum  sheet  outer  panels  (upper  and  lower)    

§  Aluminum  stamping  wiper  reinforcement  

 

 

 

Cas=ng  replaces:  

§  7  steel  stampings  including  reinforcements  in  hinge  &  latch  areas    

§  2  plasYc  pieces  §  ConsolidaYon  to  one  casYng  reduces  joining  technologies  from  84  to  10  (6  rivets  and  4  welds)  

COATINGS  Powdercoat

Cas=ng  is  coated  with  Alodine  5200  and  PPG  PCT99106  Powdercoat  in-­‐house  at  Meridian  

§  Powdercoat  primer  verified  for  compaYbility  with  the  FCA  assembly  plant  paint  system  

§  Provides  protecYon  for  the  zinc  phosphate  baths  in  the  BIW  e-­‐coat  process  from  magnesium  dissoluYon  

§  Acts  as  a  layer  of  corrosion  protecYon  for  the  casYng.  §  CompaYble  with  and  serves  as  a  clean  and  consistent  surface  for  hem  /  glass  panel  adhesive  bonding  

§  ConducYvity  is  maintained  to  aluminum  panels/brackets  through  hinges  and  regions  by  masking  prior  to  the  pre-­‐treatment  process    

BUSINESS  PROCESSES   CollaboraWve  Process The  liRgate  closure  inner  casYng  is  a  collaboraYon  between  Fiat  Chrysler  Automobiles,  Meridian  Lightweight  Technologies  and  Thai  Summit  America  Corp.  and  represents  the  first  high-­‐volume  Magnesium  applicaYon  of  its  kind  in  the  automoYve  industry  

OEM  ASSEMBLY  PLANT

Outer  Stampings  and  Hemmer

FIBER  PATCH

BRACKETS  WIPER

HEM  INNER  AND  OUTER  

PANEL MEASURE,  EVALUATE  

SHIP  TO  FCA  

Mg  Diecast  Inner

DIE  1

DIE  2

DIE  3

CASTING

CASTING

TRIM TRUING SAND  /  BUFF

POWDER  COAT

MEASURE,  EVALUATE  SHIP  TO  TSA

MULTIPLE  CAVITIES  STREAM  INTO  ONE  PROCESS

CASTING  OF  THE  YEAR  Comprehension  of  magnesium  in  automoWve  applicaWons  

INTERNATIONAL  MAGNESIUM  ASSOCIATION  2016  Award  of  Excellence  

AMERICAN  FOUNDRY  SOCIETY  2016  Metal  CasYng  Design  &  Purchasing  CasYng  of  the  Year  

NORTH  AMERICAN    DIE  CASTING  ASSOCIATION  2016  Magnesium  CasYng  over  0.5  lbs.  

CONCLUSIONS  In  summary,  the  2017  Chrysler  Pacifica  Magnesium  li_gate  inner  is  the  result  of  successful  implementaWon  of  a  comprehensive  magnesium  strategy.

§  Alloys  

§  Product  Design  

§  Galvanic  Corrosion  

§  Fastening  

§  CoaYngs  

§  Business  Process  

COMPANY PROFILE

WE  ARE  THE  LIGHTWEIGHT  HEAVYWEIGHT  Meridian  is  the  leading  full  service  supplier  of  innovaWve  lightweight  magnesium  die  cast  components  and  assemblies  in  the  global  automoWve  market.

§ Magnesium  and  Aluminum  alloy  casYng  capability    

§ World’s  largest  producer  of  magnesium  components  

§ Die  casYng  magnesium  since  1981  

§ Over  1,600  dedicated  employees  

§ 7  global  manufacturing  sites  

§  In-­‐house  design  and  advanced  engineering  § 63  total  die-­‐cast  machines  from  500  to  4,500  tons  

§ 28  die  cast  machines  2,500  tons  and  over  

§ Secondary  machining,  coaYng,  and  assembly  capabiliYes  

GLOBAL  FOOTPRINT  Meridian  Lightweight  Technologies

§  4  North  American  Manufacturing  Sites    

§  1  European  Manufacturing  Site    

§  2  Asian  Manufacturing  Sites    

§  3  InternaYonal  Sales  Offices    

Coahuila,  Mexico  Manufacturing    

Strathroy,  Ontario  Global  Technology  Center  2  Manufacturing  Facili@es  

Plymouth,  MI    Business  Development  

Munich,  Germany    Business  Development    

Shanghai,  China    Manufacturing    

Xinchang,  China    Manufacturing    

Eaton  Rapids,  MI  Manufacturing    

Noinghamshire,  UK  Manufacturing