Researching and developing products of the future

The requirements driven by environmental policy that vehicle manufacturers have to satisfy are manifold: On the one hand, supplier components need to be as light as possible in order to reduce or keep fuel consumption down through weight savings. On the other, their structure has to be sound in order to absorb or divert the impact energy in the event of a crash. This means that steels of increasingly greater strength are necessary. With material thicknesses of less than two millimeters, stable geometries must be implemented to prevent deformation or guarantee optimum energy redirection. Steel is the most cost-effective, lightweight solution to solving this task, as aluminum is much more costly and not as economical in comparison.
 
New component concepts are developed without any defined outcome together with automotive manufacturers and automotive suppliers. The process involves not only solving a specific problem, but also laying the foundation for deriving other application scenarios. The supplier knows what the market wants and which products are in demand here, and Salzgitter Flachstahl has the grades and types of steel that are best suited or can identify new ways of finding a solution. Forces are then joined to find an optimal solution. The results from tests and research form the basis for further product design.
 
As part of the cooperation with an automotive supplier, a high strength material was sought for use in side intrusion beams. The aim was as follows: The component geometry specified was to be designed in a way to render it light and rigid at the same time, with as little deformation as possible when under stress.
 
A simulation was carried out in a potential analysis initially for a sample geometry in order to identify the critical areas on the component. Tests were run to show where a swelling occurred in the forming process and where in particular cracks appear on the component when stressed. Salzgitter Flachstahl provided the material, specifically HCT780Cxpand^®, for the practical test, and the customer then carried out a static three-point bending test on the formed component. The result: The deformation set in at the points identified in the simulation, and the side intrusion beams absorbed the energy as predicted. Diverse tests ensured that crack-free forming, also with the product manufactured through the normal production process, was feasible. The potential analysis was a success – the side intrusion beam is ready to go into series production.
 
This cooperation based on a partnership between customer and Salzgitter Flachstahl resulted in finding process-compatible solutions that meet the sophisticated demands of automotive end customers for economy, safety and lightweight construction. The experts from sales and technical customer support of Salzgitter Flachstahl and Salzgitter Mannesmann Forschung are at hand to provide the customer with their know-how. The result – in this case, the side intrusion beam of HCT780Cxpand^® – speaks for itself.