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Great Designs in Steel is Sponsored by:AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
Nucor Corporation, Severstal North America and United States Steel Corporation
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The Body in White of the new BMW 5 Series Gran Turismo.
Duane CopelandBMW AG
Markus PfestorfBMW AG
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Contents
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Introduction
Personal Space- Semi Command Position- Perfect Entry- Rear Leg Room- Sedan-like Separated Trunk- Panoramic Roof
Coupe-Like Exterior- Coupe-Like Silhouette- Frameless Doors- High-Quality Appearance of Exterior - (ex. chrome and high gloss black elements)
Modern, Elegant Interior- New Type of High-Quality Interior- Extended Ambient Light- Single Rear Seat Configuration (option)
Functionality- Twin-Trunk Lid- Trunk Volume- Flexible 2nd Seat Row / Trunk Size
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Relative Product Dimensions
BMW X6BMW 7 seriesBMW 5 series Gran Turismo
1678 1456 1555
2933 3070 3070
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Technical Components for EficientDynamics
Runflat Tires
Lower CO2 Emissions
Efficient TwinPower Turbo Engines
Eight Gear Automatic Transmission with Steptronic
Double-WishboneFront Axle
Integral-V-MultilinkSuspension
Light Weight Body in White Design
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Torsional Stiffness and Lightweight CoefficientTo
rsio
nal s
tiffn
ess
c T
L = mGer
CT x A[ x 10³ ]Kg
Nm/° x m²
L Lightweight CoefficientmGer. Weight of Body-in-WhitecT Torsional StiffnessA Area (wheel base x track width)
L
27,5003.0
L
31,500
2.6
0
5.000
10.000
15.000
20.000
25.000
30.000
Nm/°
40.000
Sun RoofClosed Roof
Ligh
twei
ght c
oeffi
cien
t L
0
0,5
1,0
1,5
2,0
2,5
3,0
4,0
3,5cT
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Increase of Stiffness in the Front and Rear End
Struts Torsion Frame
SteelAluminum
Aluminum Struts
High Pressure Cast Aluminum Shock Tower
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Passive Safety
Passive safetyActive safety Crash
Correction
Driving
Warning
Crash Unavoidable Post Crash
cT
Stiffness Strength
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Load Path of Side Impact
B-Pillar
Impact
Hot Stamped Components
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USNCAP Barrier
Barrier Weight = 1368 kg
8 Cylinder 4-Wheel Drive(incl. simulated luggage)Load = 2555 kg
•Passenger Values OK•Doors Remain Closed
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Materials
OthersOther metallic materials
Aluminium
AlMg3,5MnAlMg4,5Mn0,4AlMg1/AlMg5,7/AlMg1AlMg0,4Si1,2AlSi0,6Mg0,5AlSi10MgMnFeAlMgSi
SteelDC04DX54DDX56DHC180BD, HC180YDHC220BD, HC220YDHC260BD, HC260LAD, HC260X(D)HC300BD, HC300LAD, HC300XHC340LAD, HC340X(D)HC380LADHC400THC420LAD, HC450XHC600C, HD680CHC700XHC1000W (+TE), HC1000WD+ZF
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Materials of the Structure180 MPA7%
200 – 220 MPa9%
260 MPa10%
380 - 450 MPa14%
600 - 700 MPa1%
1000 MPa12%
AlSi Aluminum2%
Others5% 300 - 340 MPa
21%
Deep Drawn Steel19%
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Weight Savings Compared to Conventional Steel Grades
Hot Stamped Parts: -20,7 kg
Shock Tower: -4,0 kg
Hood: -7 kgDoors: -16 kg
Tail Gate: -13,2 kg
Total weight savings due to lightweight material design: 60,9 kg
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Hot Stamped Parts
Uncoated MaterialZinc Coated Material
B-Pillar ReinforcementMaterial: HC1000WD+ZFThickness 1,80
B-Pillar Reinforcement InnerMaterial: HC1000WThickness 1,60
A-Pillar ReinforcementMaterial: HC1000WThickness 1,60
Longitudinal Side Member InnerMaterial: HC1000WD+ZFThickness 1,50
Tunnel ReinforcementMaterial: HC1000W+TEThickness: 1,50
Hinge Carrier ReinforcementMaterial: HC1000WD+ZFThickness 1,60
Longituidinal Side Member OuterMaterial: HC1000WD+ZFThickness 1,00
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Press Hardening Process for Zinc Coated Boron Steel
Hot dipped galvanized coil
Cold forming Austenizing + press hardening
Cleaning(optional)
Oiling (optional)
Annealing(optional)
1. Form and Trim in a conventional cold forming process.
2. Heat up the part to Austenitizing Temperature.
3. Pressharden by Quenching in a cooled die.
4. Cleaning of the parts to remove Oxide Layer (optional).
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Press Hardening Process for Zinc coated Boron Steel
Film
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Press Hardening Process Window
min. Time for Mechanical Properties (austenitization of the material)
Process Window max. Time for • Welding• Corrosion Protection• Paint Adhesion• Glue Adhesion(Oxide layer and Fe
content)
Oxide Layer
Zn Fe Coating
Basic Material
Increase of Oxide Layer
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Barrier and Cathodic Protection
100µm
50µm
Conclusion:• Protection exists even with damaged surface and along cut edges• Application in wet areas without supplementary support
B. Region along the Scratch:• Cathodic Protection • No Base Material Corrosion• Corrosion Creep of Paint:
0,4mm
C. Undamaged Region:• Barrier and Cathodic Protection
A. Overview Picture:
• Zinc Coated Hot Formed Steel after 10 weeks of testing
Zn Fe Coating
22MnB5
Iron Zinc
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Coating Properties – Zinc Distribution
Conclusion:• no zinc within the base material• no Embrittlement of grain
boundaries by zinc
22MnB5
Zn-Fe-Layer
10µm 10µm
Zinc-, Iron- Distribution
22MnB5Zn-Fe Layer
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Other Applications of Zinc Coated Boron Steel
BMW 7 series (SOP 2008) BMW 5 series (SOP 2010)
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Application of Dual Phase Steel
Dachrahmen innen hinten an Serienstand angepasst 14.09.09
Steel Grades
HC260XDHC300XHC340X(D)HC400THC450XHC600C, HD680C
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Work Hardening of Dual Phase Steel (HC450X)
Specimen
1
2
Thinning
Bent Part
Deep Drawn Part
Section 1 Section 2
548 MPa 557 MPa
767 MPa 580 MPa
Measured Yield Strength
min.
max.
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Thank You for Your Attention
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Great Designs in Steel is Sponsored by:AK Steel Corporation, ArcelorMittal Dofasco, ArcelorMittal USA,
Nucor Corporation, Severstal North America and United States Steel Corporation
