ultra lightweight reinforcement for advanced high …...w w w . a u t o s t e e l . o r g ultra...
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Ultra Lightweight Reinforcement for Advanced
High-Strength Steel Body and Closures
Mansour Mirdamadi
Deep Wang
Dow Automotive Systems
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Presentation Outline
• Introduction to BETAMATETM epoxy Light Weight Reinforcement (LWR)
• LWR material performance attributes
• Component testing studies
• LWR CAE validation studies
• Case studies
• Conclusions
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BETAMATE Light Weight Reinforcement (LWR)
Typical body B-Pillar Structural
BETAMATE
Structural BETAFOAM
LWR
• What is LWR
Body shop applied BETAMATE epoxy material
Developed based on characteristics of highly toughened epoxy based adhesive
Designed to have expansion characteristics of 150%
Designed joint BIW substrates having gaps up to 15 mm
Highly mass efficient solution
Provide crashworthiness and body stiffness improvement
Application method
Stream
Swirl
Bead
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BETAMATE LWR
Expansion Sensitivity
Substrate: 0.8mm HDG steel,
Temperature exposure 30’ @ 170°C
Bond thickness 0.25mm
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BETAMATE LWR
Expansion Sensitivity
7mm
3mm 2mm 1mm < 0.5mm
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BETAMATE LWR Toughness
Performance Wedge impact peel performance of 9.0 N/mm
Cohesive failure mode
Plastic deformation of the substrate demonstrates BETAMATE LWR toughness
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Class-A Read Through Studies
A: Roof panel to roof bow Observed read through
B: B-Pillar No visible read through
C: C-Pillar No visible read through
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Prototype Component Tests
welds
0.75 in 2.0 in
5mm gap
120mm 38mm
All layers are
0.8mm mild steel
EG surface
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High Speed Component Testing
20 MPH
70 lb mass
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BETAMATE LWR CAE Correlation
Component Bending Response
Quasi-static
Dynamic Bending
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Vehicle Crashworthiness Fit
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B-Pillar Side Impact Component
Study
B-Pillar inner: DP590
B-Pillar outer/outer reinforcement: DP980
Requirements
Peak load of 50 kN
Peak bending moment of 10.5 kN.m
Assumptions: 1kg of mass savings worth $5 kg
Beam 3 point bending study
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B-Pillar Side Impact Component
Study Added LWR mass = 197g
B-Pillar outer 1.2 1.0 mm
Reinforcement 1.6 mm 1.4 mm
Sheet metal saving of 1.0 kg
Cost increase delta on based on material
$2.67
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BETAMATE LWR Roof Crush Study
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BETAMATE LWR Location
Sensitivity Study
LWR 7 LWR 6
LWR 3
LWR 2
LWR 1
LWR 8
LWR 4 LWR 5 LWR 9
0.39 kg
0.40 kg
1.16 kg 0.60 kg 0.18 kg
0.95 kg 0.47 kg
0.30 kg
0.20 kg
Total LWR Mass: 4.65 kg
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BETAMATE LWR Location
Sensitivity • The critical locations for LWR
– LWR 8: B-pillar
– LWR 1: A-pillar middle joint
– LWR 7: C-pillar upper joint
– LWR 3: A pillar upper joint
- reinforcement (Negative)
– LWR 6: Roof rail rear gap
• The critical interaction variables
– LWR 3 * LWR 4
– LWR 2 * LWR 4 (Negative)
– LWR 3 * LWR 6 (Negative)
LWR 1
LWR 8
LWR 7
LWR 3
LWR 6
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BETAMATE LWR Optimum
Locations • The optimum LWR mass is 1.14 kg
• Peak force is 63.0 kN, increase 21 %
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BETAMATE Application to
IIHS Narrow Offset
BETAMATE toughened epoxy
body flange bonding ~ 100 m
BETAMATE LWR
body cavity treatment ULWR Optimized #2
0.9kg/side
Baseline vehicle
response
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BETAMATE Application to
IIHS Narrow Offset
BETAMATE LWR
body cavity treatment
BETAMATE CDA Flange
Bonding
BETAMATE CDA Flange
Bonding & LWR
Baseline
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Narrow Offset Intrusion
Comparison
Intrusion
improvement
benefits
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Conclusions
• LWR will enable OEMs and Tiers to reinforce small body cavities with highest performance and lowest mass by using proven crash durable bonding technology
• LWR provides opportunity to
– Outperform conventional expandable adhesive solutions. Less mass is required in achieving same level of performance
– Enhance energy absorption and load-transfer between body structure components
– Join sheet metal components where gaps and joining is not suitable for conventional metal joining or conventional adhesive bonding
– Optimize body components that are not traditionally considered in design process for meeting new safety and stiffness requirements
• Body shop applied material using the same dispensing equipment used for BETAMATE adhesive bonding
• Vehicle body strength/crashworthiness applications
– IIHS side impact
– Roof crush
– Frontal moderate, and narrow offset impact
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North American
Light Vehicle Metallic Material Trends
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