Ensuring  Manufacturing  Infrastructure  Readiness  

Dr.  Paul  E.  Krajewski  General  Motors  Company  

GALM  2013  

Outline  Define  Scope  of  Problem  Key  Questions  Material  Product  Development  Forming  Assembly  /  Joining  Painting  Execution  Summary  

Back  to  the  Future  

1909  Ford  Model  T  Touring  Car  

Aluminum  Hood,  1915  Model  T  

It  is  difficult  to  define  manufacturing  

lightweighting  approaches.  

Audi  A8  

http://media.windingroad.com/autos_db/lists/3-­‐Aluminum_Space_Frame_jpg_667x667_q100.jpg  

Plastics  Omnium  

http://www.scoop.it/t/evolution-­‐et-­‐inovation-­‐auto  

MIXED  MATERIALS  SOLUTIONS  

ATS  Material  Selection  Mild  Steel    Bake  Hardenable    HSLA    Dual  Phase    Martensitic    PHS    Al  

 

BMW  i3  &  i8  

Carbon  Fiber  

Aluminum  

http://www.eurocarnews.com/media/pictorials/1483/7130.jpg  

Audi    Mixed  Materials  

Aluminum     Carbon  Fiber  

Key  Light-­‐weighting  Questions  

Need  to  define  overall  strategy  What  vehicle  segment  /  price  point  /  volume?  What  is  the  value  of  mass  on  the  program?    Global  or  regional  execution?  Which  materials  and  parts?  Where  will  parts  be  produced?    Make  vs.  Buy  What  assembly  /  joining  technique  will  be  used?  

Manufacturing  Value  Stream  

Material  

Raw  material  availability    geography  Conversion  to  sheet  /  extrusion  /  ingot  Preparation  for  forming    pretreatment  Blanking  vs.  Coils  

http://en.wikipedia.org/wiki/File:Extruded_aluminium_section_x3.jpg  

Key  Material  Issues  PHS  

Prototype  infrastructure  Material  suppliers  with  Zn  coating  

Aluminum  Heat  treat  capacity  Structural  casting  infrastructure  

Magnesium  Limited  supply  base  for  low  cost  sheet  and  HPDC  90%  of  material  produced  in  China  

Composites  Low  density  SMC  Class  A  /  Painting  Dimensional  stability  /  fit  

Carbon  Fiber  Overall  Industry  capacity  low.  North  American  supply  base  limited.  

Lightweight  Material  Capacity  

Aluminum  2012  NA  capacity  for  heat  treated  Al  sheet  90kT.  An  AIV  with  400,000  APV  requires  90  kT.        

Carbon  Fiber  A  carbon  fiber  intensive  body  and  closures  at  200,000  APV  would  consume  global  fiber  capacity.  

Product  Development  Issues  

Overall  lack  of  experience  with  lightweight  materials.  Lack  of  design  for  manufacturing  (DFM)  information.  CAE  database  for  materials  and  joints.  

Opportunity  for  industry  collaboration  

Develop  best  practices.  Acoustic  management.    

Primary  Forming  PHS  

Hot  forming  lines  required  Typically  done  in  supply  base  

Aluminum  Can  use  existing  steel  infrastructure  Need  more  dies  (5-­‐6)  different  lubricants.  Scrap  segregation  

Magnesium  Requires  thermal  assisted  forming  Die  casting  infrastructure  limited.  

Composites  SMC  supply  base  limited.  Long  cycle  time  Improved  formability  compared  to  steel/Al  

Carbon  Fiber  North  American  supply  base  limited  Long  cycle  time  

Need  to  develop  new  processes  to  enable  mixed  material  vehicle  executions.  

  Decide  whether  performing  in-­‐house  or  at  suppliers     Accurately  forecast  usage  to  assure  capacity      

 Form Press

Form Tool

Destack Robot

Blank Stack

Blank PresentationFixture

Blank Pre-Heater

Press Automation

Exit Conveyance

Operator Station &

Ergonomics

Hot ToolCleaning Robot

Cooling Fixture

Location

Form Press

Form Tool

Destack Robot

Blank Stack

Blank PresentationFixture

Blank Pre-Heater

Press Automation

Exit Conveyance

Operator Station &

Ergonomics

Hot ToolCleaning Robot

Cooling Fixture

Location

 

Secondary  Forming  Trimming  Clinching  Hemming    

BENDING  MAGNESIUM  FOR  AUTOMOTIVE    

AZ31  Magnesium  

Assembly  /  Joining  PHS  

Need  new  welding,  fastening  and  bonding  techniques  

Aluminum  Spot  welding  compatible  with  steel?  Riveting  Adhesive  bonding  without  pretreatment  

Magnesium  Need  heated  clinching  /  fastening  Corrosion  isolation.  

Composites/Carbon  Fiber  Closure  assembly  at  Tier  supplier  Need  bonding  /  fixturing  experience  Surface  effects  /  read-­‐through  

Painting  

Aluminum  and  PHS  can  be  processed  through  conventional  paint  lines.  Al  /  Steel  mix  can  require  varying  phosphate  bath  chemistry  Paint  bake  temperature  can  affect  aluminum  properties  and  will  affect  composites.  Magnesium  need  to  be  coated  prior  to  painting/assembly  Composites  usually  painted  offline  and  installed  in  General  Assembly.  

The  easiest  approach  to  enabling  the  use  of  lightweight  materials  is  a  dedicated  plant.  

Bowling  Green  Assembly  

Hydroformed  Al  Frame  Rails  

Carbon  Fiber  Floor  Pan  

Mg  Engine  Cradle  

Ti  Valves  and  Connecting  Rods  

Mg  Roof  Frame  Hydroformed  Al  Roof  Bow  

Corvette  Z06    

Corvette  Stingray  

Aluminum  Frame  

 

Tube  Hydroforming  

Composite  Painting  

Corvette  Assembly  

Camaro  

Camaro  ZL1  

Global  Multi-­‐Plant  Platform  

Key  Issues/Questions:  Common  execution  or  regional  variation  Model  changeover  strategy  Are  multiple  architectures  built  in  same  plant  Dedicated  or  flexible  body  shop  

Summary    

The  increased  use  of  lightweight  materials  will  require  capital  investment  and  increased  piece  cost.  Impact  can  be  minimized  with  clear  strategy  and  long  term  vision.  A  long  term  strategy  is  essential  to  making  sure  the  value  chain  is  ready  for  execution.