Final Seminar 24th Feb. 2016 WP7 | Tasks 7.1, 7.3, 7.4 and 7.5

Use of magnetic pulse to join composite to metal for shock absorber application

Author(s):

Emilie Boulay - TENNECO

Date: 24/02/2016 – Ghent

Tenneco

1943: Build gas pipeline 1991: Spun off Automotive Packaging (1999) Farm and construction equipment Chemicals Gas transmission Ship building

2005: “Tenneco„ instead of Tenneco Automotive => ride control products => emission products

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Global supplier of Clean air, Ride Performance systems

A) Emission Control Systems (CA) • Fabricated Manifolds

• Manifold Converters

• Downpipes

• Converters

• Particle Filters

• Mufflers

• Complete Exhaust Systems

B) Ride Control Systems (RP) • Shock Absorbers

• Struts • Suspension Modules • Electronic Suspension

• Springs

• Elastomers (Clevite)

• Anti-roll system C) Elastomers (EL) • NVH components

• Clevite, Suzhou, Axios

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Lake forest, Illinois

St-Truiden

21.000

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TENNECO RC European presence

EU RC 1. St-Truiden (BE) 2. Ermua (ES) 3. Gijon (ES) 4. Hodkovice (CZ) 5. Gliwice (PL) 6. Port Elizabeth (SA) • Hosur (IN) • Beijing (CH)

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Metalmorphosis : targets for Tenneco

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The state of the art monotube dampers are being produced out of a steel tube

which is hot formed at the bottom and a loop welded to the tube

The EMJ technology would allow to replace the steel loop by an integrated composite loop which would be fixed to the tube

Benefits: 1. Weight savings supporting the CO2 emissions

strategy from the european commision 2. Cost saving improving the competitivity Selected metals: steel / aluminium Target: structural part requirements

Requirements

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OIL

GAS

High axial load (rebound/compression)

High durability

Minimum bending

Temperature resistance

Gas tightness

Impact resistant

Basic objectives of the suspension 1) Provide steering stability with good handling

characteristics. 2) Maximize passenger comfort. Primary purpose shock absorber: Control suspension

movement

WP7 - Outlines

Task 7.3: Physical tests on simplified parts (BWI) Determination of groove concept Process parameters

Task 7.1: Design of demonstrator Simulation (PTG-TEN)

Material models for metal and plastic Crimping deformation Tensile test

Groove design Loop design

Task 7.4: Tests on demonstrator (BWI-TEN) Task 7.5: Evaluation Conclusion and possible improvements

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Task 7.3 : Groove design, material and energy (BWI)

Composite specimen fracture behaviour Observations :

All composite inner diameters: similar impact resistance

At higher discharge energies: plastic deformation at groove bottom and groove edges, due to thermal effects of steel tube

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Observations :

Steel tube : no fracture, only expansion of steel tube after testing

Composite : 3 different fracture modes, depending on composite inner diameter and discharge energy:

– No composite fracture – Composite fracture outside

groove zone – Composite fracture at

plastically deformed groove bottom

– Increase of energy ⇒ increase of tensile force

Task 7.3 : Groove design, material and energy (BWI)

Tensile strength

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No steel tube fracture +

No composite fracture

No steel tube fracture +

Composite fracture outside groove zone

No steel tube fracture +

Composite fracture at plastically deformed

groove bottom

23,2 kN at 14 kJ 36,7 kN at 18 kJ 33,4 kN at 18 kJ

Task 7.3 : Groove design, material and energy (BWI)

Tensile test: 3 fracture modes of the steel tube

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Simulation of the deformation tube in the groove Signal using anisotropic material with strain rate dependency and failure

model. Failure behavior provided to PTG to calibrate the model Geometry check + comp with meas. of the physical parts Axial pull test + comparison of the experiments

Task 7.1 – Design of the demonstrator

(source: Deliverable D2.2, Tenneco/Stam)

Force data

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Steps: tube deformation and pull

Task 7.1 – Design of the demonstrator

Compromise between constant/limited thickness and

17 mm

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Groove and loop design

⇒ Increase of tensile force: - after use of a steel bar in the composite loop - at a higher discharge energy

⇒ Strenght too low according to requirements

As-crimped connection: without bar Modification of crimped connection: with bar

Fracture in the eye of the composite loop Fracture at the groove edge

18,7 – 20,3 kN 22,2 – 23,8 kN

Task 7.4 – Test on final demonstrator 1st composite batch: tensile force

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As-crimped connection : without bar Modification of crimped connection : with bar

Fracture in the eye of the composite loop

or fracture at the groove edge

Only fracture at the groove edge

19,9 kN 17,1 – 18,8 kN 19,6 – 22,6 kN

1st composite batch: tensile force

Task 7.4 – Test on final demonstrator

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Composite Metal tube Concept 3 Concept 7

Preliminiary experiments

PA6.6 GF30 (bar)

Steel E235+C 22 – 29 kN

[at 13 – 15 kJ ]

33 – 40 kN

[at 13 – 15 kJ ]

Akulon K224-PG8 (tube)

Aluminium 6082

20 – 31 kN

[at 7 – 10 kJ]

-

Akulon K224-PG8 (tube)

Steel E235+C

23 – 37 kN

[at 14 – 18 kJ]

-

Final

experiments

PA6.6 GF30 (with mould)

Steel E235+C

17 – 24 kN

[at 14 – 16 kJ]

-

Task 7.4 – Test on final demonstrator

Overview : Range of tensile forces & discharge energies

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Task 7.4 - Characterization of the demonstrators Tensile tests

20-23 kN (below the target fixed) Failure above the groove only

Impact test: not ok at 13 kJ / ok at 10 kJ impact on join strength ?

Durability Low (expected) At 80 °C: no sign. decrease in strength reg. 25 °C 120 and 150 °C will be tested again after

improvement Idem for bending and corrosion resistance

Gas tightness Ok at the groove/ join between metal and composite NOK due to a crack formed after crimping

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OK

NOK

Conclusions Main results

Concept selection: compromise cost/requirement (60 % weight saving, +0,1 € max)

EMJ parameter selection Free deformation and material model correlated with experiment

Confirmation of the design robustness (static / durability) New FEA simulations with optimized design Take the second groove into account in deformation simulation as well as

the complete geometry in tensile test simulation

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Join between steel tube and composite are clearly not the weak point regarding strength, tightness or temperature resistance !

Optimization of joining processes for new automotive metal-composite hybrid parts

Grant Agreement Nr: 609039 Collaborative Project - FP7-2013-NMP-ICT-FOF(RTD)

Thank you! Q&A ?