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7/31/2019 50 Year Perspective of Automotive 50 Year Perspective of Automotive Engineering Body Materials and an Engineering Body Materials and an Analysis of the Future Analysis of
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50 year Perspective of Automotive50 year Perspective of Automotive
Engineering Body Materials and anEngineering Body Materials and an
Analysis of the FutureAnalysis of the Future
Jody N. HallJody N. Hall
Manager, Global Die Standards & Materials ApplicationsManager, Global Die Standards & Materials Applications
General Motors Manufacturing EngineeringGeneral Motors Manufacturing Engineering
Great Designs in Steel 2008Great Designs in Steel 2008
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Steel Becomes theSteel Becomes the Material of ChoiceMaterial of Choice
for Auto Bodiesfor Auto Bodies
Original bodies made of wood& steel
Quick to tool, easy to change
Large number of skilled
workers
1914 Dodge & Budd produce5,000 all-steel bodies
All-steel body was lighter,stronger, easier to make
Most significant advantage wasin painting
Benz Patent Motorwagen 1886 (Replica)
Dodge Brothers Touring Car 1917
http://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpghttp://upload.wikimedia.org/wikipedia/commons/4/40/1917_Dodge_Touring_Car.jpghttp://upload.wikimedia.org/wikipedia/commons/4/40/1917_Dodge_Touring_Car.jpghttp://upload.wikimedia.org/wikipedia/commons/4/40/1917_Dodge_Touring_Car.jpghttp://upload.wikimedia.org/wikipedia/commons/4/40/1917_Dodge_Touring_Car.jpghttp://upload.wikimedia.org/wikipedia/commons/4/40/1917_Dodge_Touring_Car.jpghttp://upload.wikimedia.org/wikipedia/commons/5/53/Benz_Patent_Motorwagen_1886_%28Replica%29.jpg7/31/2019 50 Year Perspective of Automotive 50 Year Perspective of Automotive Engineering Body Materials and an Engineering Body Materials and an Analysis of the Future Analysis of
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Every time the price ofEvery time the price ofsteelsteel goes up,goes up,DetroitDetroits auto makers moan in anguishs auto makers moan in anguish
and intensify their search forand intensify their search for
replacementsreplacements
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Every time the price ofEvery time the price ofsteelsteel goes up,goes up,DetroitDetroits auto makers moan in anguishs auto makers moan in anguish
and intensify their search forand intensify their search for
replacementsreplacements
gasgas
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Materials Causing the Biggest Stir in BodyMaterials Causing the Biggest Stir in Body
TechnologyTechnology
PlasticsPlastics--been getting the big playbeen getting the big play
as successor to steelas successor to steel
Aluminum AlloysAluminum Alloys--about as strong as steel,about as strong as steel,
less than half the weightless than half the weight--usedused since birth of autosince birth of auto
--most plentiful metal on earthmost plentiful metal on earth
Magnesium AlloysMagnesium Alloys
--even lighter than aluminum,even lighter than aluminum,stronger for its weight than steelstronger for its weight than steel
--most easily machined and castmost easily machined and cast
--enough in the oceanenough in the oceanto provide 100,000,000 tons a yearto provide 100,000,000 tons a year
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Published October 1953
The day of the passengercarmade primarily of ironand steelis on the wane!Some sources predict that
by 1960a Cadillac will weighless than a 1953 Chevroletand a Chevy will probablyweigh about as much as amotorcycle.
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Prediction 50+ Years AgoPrediction 50+ Years Ago
SteelAl Plastics
Mg
FUTURE
PAST
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Steel Mass ReductionSteel Mass Reduction
Time
M
assReduc
tion
Opportunity
0%
20%
10%
30%
40%
50%
1970 1990 2000 2010 20201980 2030
MILD STEELS
CONV HSS
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54.6%
12.7%
15.8%
0.8%9.5%
6.6%
Current Body and Closure Metallic MaterialCurrent Body and Closure Metallic MaterialContent by Type for North AmericaContent by Type for North America
Mild SteelMild Steel
MediumMedium
HSSHSS
850 Pounds850 Pounds
AdvancedAdvanced
HSSHSS
BakeBake
HardenableHardenable
SteelSteel
ConventionalConventional
HSSHSS
Aluminum &Aluminum &
MagnesiumMagnesium
Source: Ducker WorldwideSource: Ducker Worldwide
20072007
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The Question isThe Question is
Why do these materials continue to fall
short of the prediction?
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Comparison of Materials by PerformanceComparison of Materials by Performance
Density Modulus Tensile
Strength
Elongation Corrosion
Resistance
Mild Steel
Aluminum ++ -- 00 00 0 /0 / ++
Magnesium ++ -- -- 00 -- 0 /0 / --
Polymers &Composites ++ 0 /0 / -- --/ 0 // 0 / ++ -- ++
- - - - - - - - - - BASELINE - - - - - - - - - -
KEY: 00 = equal ++ = better -- = worse
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Comparison of Materials byComparison of Materials by
Other Important CharacteristicsOther Important Characteristics
CostCost
(Est. $/lb.)(Est. $/lb.)
AvailabilityAvailability(Annual Metric Ton(Annual Metric Ton
Production)Production)
EnvironmentEnvironment(Primary Production Emissions(Primary Production Emissions
reported by industry)reported by industry)
Mild SteelMild Steel
(Baseline)(Baseline)$0.50$0.50 110 Million110 Million easy to recycleeasy to recycle
Emissions = 2.3Emissions = 2.3 2.7 kg CO2.7 kg CO22/kg/kg
AluminumAluminum
(Al)(Al)
$1.00$1.00 2.5 Million2.5 Million easy to recycleeasy to recycle
Emissions = 13.9Emissions = 13.9 15.5 kg15.5 kg
COCO22/kg/kg
MagnesiumMagnesium
(Mg)(Mg)
$1.50$1.50 0.5 Million0.5 Million easy to recycleeasy to recycle
Emissions = 18.0Emissions = 18.0 24.8 kg24.8 kg
COCO22/kg/kg
PMCPMC $1.20$1.20 --
6.506.50UnknownUnknown difficult to recycledifficult to recycle
Emissions = 2.5Emissions = 2.5 23.0 kg CO23.0 kg CO22/kg/kg
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6.6%
9.5% 0.8%
15.8%
12.7%
54.6%
Current Body and Closure Metallic MaterialCurrent Body and Closure Metallic Material
Content by Type for North AmericaContent by Type for North America
Mild SteelMedium
HSS
850 Pounds850 Pounds
AdvancedHSS
BakeHardenable
Steel
Conventional
HSS
Aluminum &Magnesium
Source: Ducker Worldwide
2007
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Comparison of Materials by PerformanceComparison of Materials by Performance
Density Modulus Tensile
Strength
Elongation Corrosion
Resistance
Mild Steel
Aluminum ++ -- 00 00 0 /0 / ++
Magnesium ++ -- -- 00 -- 0 /0 / --
Polymers &
Composites
++ 0 /0 / -- --/ 0 // 0 / ++ -- ++
HSS/AHSS 00 00 + ++ + 0 /0 / -- 00
- - - - - - - - - - BASELINE - - - - - - - - - -
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Comparison of Materials by ManufacturabilityComparison of Materials by Manufacturability
Steel &Steel &
HSS/AHSSHSS/AHSS
AdvantagesAdvantages::
FormabilityFormability
WeldabilityWeldability
InfrastructureInfrastructure
Painted SurfacePainted Surface
DisadvantagesDisadvantages::
CastabilityCastability
AluminumAluminum
AdvantagesAdvantages::
FormabilityFormability
CastabilityCastability
Painted SurfacePainted Surface
DisadvantagesDisadvantages::
LowerLowerformability thanformability than
steelsteel
WeldabilityWeldability
MagnesiumMagnesium
AdvantagesAdvantages::
CastabilityCastability
DisadvantagesDisadvantages::
FormabilityFormability ElevatedElevated
temperaturetemperature
stamping &stamping &
hemminghemming
WeldabilityWeldability
Polymer/Polymer/
CompositesComposites
AdvantagesAdvantages::
Low costLow cost
toolingtooling
Shorter leadShorter lead
timetime
DisadvantagesDisadvantages::
Cycle TimeCycle Time InfrastructureInfrastructure
Difficult toDifficult to
repairrepair
PaintedPainted
SurfaceSurface
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Comparison of Materials byComparison of Materials by
Other Important CharacteristicsOther Important Characteristics
CostCost
(Est. $/lb.)(Est. $/lb.)
AvailabilityAvailability(Annual Metric Ton(Annual Metric Ton
Production)Production)
EnvironmentEnvironment(Primary Production Emissions(Primary Production Emissions
reported by industry)reported by industry)
Mild SteelMild Steel
(Baseline)(Baseline)$0.50$0.50 110 Million110 Million easy to recycleeasy to recycle
Emissions = 2.3Emissions = 2.3 2.7 kg CO2.7 kg CO22/kg/kg
AluminumAluminum(Al)(Al)
$1.00$1.00 2.5 Million2.5 Million easy to recycleeasy to recycle
Emissions = 13.9Emissions = 13.9 15.5 kg15.5 kg
COCO22/kg/kg
MagnesiumMagnesium
(Mg)(Mg)
$1.50$1.50 0.5 Million0.5 Million easy to recycleeasy to recycle
Emissions = 18.0Emissions = 18.0 24.8 kg24.8 kg
COCO22/kg/kg
PMCPMC $1.20$1.20 --6.506.50
UnknownUnknown difficult to recycledifficult to recycle Emissions = 2.5Emissions = 2.5 23.0 kg CO23.0 kg CO22/kg/kg
HSS/AHSSHSS/AHSS $0.55$0.55 Included in MildIncluded in Mild
SteelSteel
easy to recycleeasy to recycle
Emissions = 2.3Emissions = 2.3 2.7 kg CO2.7 kg CO22/kg/kg
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Engineering StrategyEngineering Strategy
MaterialsMaterials
ManufacturingManufacturing
DesignDesign
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Global MarketGlobal Market
North America
Well developed market
Consumer demand for largevehicles
Relatively low fuel prices
Primary challenges U.S. CAFEand emissions regulations(particularly diesel); strictcollision performancerequirements
Latin America, Africa & Middle East
Diverse market
New market players
Lead in alternative fuels,particularly ethanol
Primary challenge is productcost
Opportunity for more growth
Europe
Well developed market
Consumer demand for a balance of
utility & efficiency
Relatively high fuel prices
Taxes on poor fuel economy &emissions
Primary challenges CO2 commitmentand Euro 5 emissions; strict collisionperformance requirements
Asia Pacific
Fast growing diverse market
Infrastructure still developing
Primary challenges are new fueleconomy/emission regulations
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Conclusions
Always be a need/desire to push tolightweight materials for the auto industry
Doesnt mean no steel
Current prediction is mainly some form ofsteel
Best value to customer (performance/cost)
However, disruptive event(s) is as likely, or
even more likely, than ever before