PSA Group - When Metal Meets Composites PDF

When Metal meets Composite
Challenges of Multi-material Joining
Mathieu Kielwasser Rf. Doc. Info. : 01376_17_00198

DQI/PMXP/MCPV
Summary
1. Regulation Context, Issues and Target
2. Current Joining Processes
3. Challenges of Multi-material Joining
4. The Project Fast Lite Assemblage
5. Outlook
Mathieu Kielwasser Research and Development Composite / metal Joining - Challenges of Multi-material Joining 2
01
REGULATION CONTEXT, ISSUES AND TARGET
Regulation Context, Issues and Target
Materials Evolution in Automotive History
Regulation Context, Issues and Target
Introduction of new material
02
CURRENT JOINING PROCESSES
Current Joining Processes
Material on New Peugeot 308
Body Hang on parts

1%
14%
11%
5%
8%
26% 6% Thermoplastic
DUROPLASTIC
2%
Al 5xxx
PHS
Al 6xxx
AHSS 30%
PHS
34% AHSS
HSS
HSS
LSS
LSS
36%
28%
Material mix Material mix

Body Hang on part
Joining processes
Peugeot 308 : mainly steel CEB design Joining techniques Joints number (#)
Seam lenght (mm)
Spot Welds (steel) 3578

2,93% Full Rivet 10
0,93%
0,64% Clinch Connection 16
6,37% Adhesive
2,40%
0,48%
Hemming Connections 18 200 mm
0,57% MAG welding
Laser Brazing (steel) 3 314 mm
MIG brazing
Remote Laser welding (steel) 8 774 mm
Remonte Laser Welding
MIG Brazing 670 mm
Laser brazing
MAG Welding (steel) 970 mm
85,68%
Clinch Adhesives 40 700 mm
Rivet thereof
RSW structural adhesive 1 190 mm
supporting adhesive 17 060 mm
hemming adhesive 18 200 mm
Joining figures sealing adhesive 4 250 mm
Introduction of semi-structural composite parts
Examples with tailgate : C4 Picasso, New 308, DS3, 508, 807
New Peugeot 308 Citron C4 Picasso
New Peugeot 308 Spoiler :
Inner door panel ABS
PPGFL 40%
Skin :
Spoiler PP
glued
Steel insert ABS-PC
overmoulded
Lock reinforcement
screwed Lower skin glued
PP EPDM T30% Inner door panel :
SMC
Composite Tailgate
Material Thermoplastic (PA,PP) thermoset (SMC)
Weight saving ~ 30% weight reduction
Joining process Composite/Composite : adhesive bonding

Composite/Steel : screwing, overmolding
Introduction of semi-structural composite parts
EMP2 Platform : Rear overhang with a composite floor
EMP2 Platform Rear composite floor Metallic Insert
Central insert
for long version
Composite rear floor
Material SMC UP-GF29-MD30
Weight saving 2,2 kg 40% weight reduction Spot welding
Introduced in bodyshop World premire

62 spots welding for
308 Peugeot Berline
Joining process : Metallic insert with spot welding
overmolding
No influence for body shop process
Innovation : Introduction of structural parts
Door with composite door side impact beam
Protection part for lateral crash Woven Injected Door

Reduced the intrusions part Part reinforcement
Part subjected to electrophoresis
Maxi 210C, during 30 min
Material : Glass fiber (fabric) + PA 6,6
Process : thermo-compression (stamping)
Fusion temperature PA 6,6 = 280C
Joining process
Metallic insert with spot welding
No influence for body shop process
Other studied joining processes

FDS Flow Drill Screw
Visible and sharp tip (dangerous for operator)
Rivet
Cracks on the composite side
2 ways for a body shop introduction
Composite with metallic insert Composite without metallic insert
Bodyshop process stand-by Cost reduction of composite part

Use of standard joining process : spot welding Mass reduction
Expensive composite part Introduction of new joining process(es)

Mechanical behavior of the overmoulding Body shop investment
Additional mass of the insert Mastery of the joining process
Modeling of the mechanical behavior
New design specifications
Change of the architecture of bodyshop line
Training of the operator
Other solution: assembly shop introduction
03
CHALLENGES OF MULTI-MATERIAL JOINING
Challenges of multi-material joining
Relevant fields for mastered introduction of a joining process
Non exhaustive joining processes available
Huge number of processes

In the case of multi-material joining only mechanical joining and adhesive bonding are possible
Example of mechanical joining process
FDS EJOWELDCFF EJOWELD RIVTAC RIVSET RIVSET HDX

Screw Pin form Nail Form Nail Rivet Rivet for UHSS
RIVKLE SFC EJOT TSSD

Blind Rivet Pin form
Example of mechanical joining limitation
Joining process direction according to the sheet stack : example with riveting
Thickness limits of the sheet stack

Cracks
Flow drilling limitation depending of Riveting limitation

the thickness and steel grad the lower sheet thickness > 1mm
Ex. : HR45 < 1,8 mm with a PA66 1,6mm
Joining composite with PHS and AHSS
Riveting limitation with standard rivet

in the case of 22mnB5 steel grade
Example of mechanical joining limitation
Unilateral accessibility
Configuration non compatible
with riveting
Volume of the mechanical joining component
FDS Flow Drill

Screw
Visible and sharp tip
Need preparation : Pre-drilled hole
Ejotweld limitation Burns

without hole
A response of all these limitations required several joining process
Not a appropriated answer to limit the cost
Composite difficulties : generation of default
Cracks
Delamination and cut of the fabric
A response of all these defaults required several joining processes

Not a appropriated answer to limit the cost
Composite difficulties : the dust with thermoset composite
Dust pollution during preparation (cutting and drilling of the composite)
Composite edge
Tooling pollution Floor and clamping system pollution
FDS equipment Riveting die Clamping system Test equipment Floor

Influence on equipment reliability and on the operator health
Solution : Environment adaptation by aspiration
Increase of the invest and running cost
04
THE PROJECT FAST LITE ASSEMBLAGE
THE PROJECT FAST LITE ASSEMBLAGE : The Partnership
The joining partners Modeling software partners
Automotive
OEMs
Academic partners Composite industry partners
The joining partners

Competence in thermal, mechanical and bonding processes
Automotive OEMs
Product specification, modeling specification, vision of industrial process integration,
Academic partners
Scientific competences in behavior and modeling of joining
Modeling software partners
Software modeling specification and modeling skills
Composite industry partners
Product simulation, materials implementation, vision behavior of joins
THE PROJECT FAST LITE ASSEMBLAGE : Organization and Figures
Steering Committee Meeting

Number 47 meeting + 3 seminars
Frequency 1/month
Starting 01.2013
Technical meeting
~ 30 on-site meetings of partners (Solvay, UVHC, ENSTA, CETIM, Bollhoff ...)
... more 200 technical points in audio
366 documents generated on the server at November 25, 2016
Materials
7 main materials, 10 "more exotic" grades
23,000 samples ...
250 toolboxs manufactured and tested
180 shipments between 12 partners
Joining techniques
18 evaluated joining techniques
57 glues listed 13 adhesives in pre-study 4 glues in study 2 glues with law materials
New methods defined
New protocols to imagine (static, crash or fatigue)
Expenses distribution
6.8 million in total
THE PROJECT FAST LITE ASSEMBLAGE : Planning
Description
Anne
Year 11 Anne
Year 22 Anne
Year 3 Anne
Year 44
Lot
WP Descriptif Pilote
Pilot
2013 2014
2014 2015
2015 2016
2016
Lot
WP00 Gestion de projet
Project management PSA / Renault
Dfinition
Definition de la toolbox
of the toolboxetand
des
Lot
WP11
procds dassemblage
joining processes
CETIM
Caractrisation et modlisation de
WP22 Characterization and modeling
Lot PSA
la
of tenue des assemblages
the joining strength
Mise au point of
Development desjoining
procds
Lot
WP33
processes
dassemblage
Renault
WP44 Assemblage de dmonstrateurs

Joining of demonstrators from + 3 months
Lot
otherdes
issus projects
autres projets
CETIM
Lot
WP55 Industrialisation
Industrialization PO
WP66 Recyclabilit
Lot Reparability and
Finend of life
de vie CETIM
Project startup J1 J2 End

8/01/2013 June 2014 June 2015
THE PROJECT FAST LITE ASSEMBLAGE : Highlights
Evaluation of joining processes
The perimeter has increased: 60 configurations 150 configurations
Evaluation of static and fatigue joining
Innovations: ex. Rivkl Bollhoff SFC presented at JEC 2015
Toolboxs
250 omega made with 5 materials
Of which 1 not originally planned PA66 woven twill
New experimental means imagined
Assembly technique tested: riveting, gluing and gluing with riveting
Scientific work
2 theses and 1 post-doc
1 new protocol to determine the fatigue performance of glue
University publications: articles + posters
Demonstrators
1 demonstrator from the DEMOS project
Design and testing of 5 seat frames with different joining techniques
Investment and running cost estimation

Consideration of a real context: PSAs floor load
Evaluation of investment and running costs according to some joining processes
Composite / Composite Few joining solutions

joining
Bonding / Welding (Laser / US ...)
Tensile shear strength
200/800 daN Mechanical joining
(Rivkle SFC ...)
Composite / Metal More joining solutions

joining
More variety of mechanical joining
Tensile shear strength (Rivet / FDS / Ejoweld ...)
300/800 daN And/or with Bonding
Welding (Laser / US ...)

requires texturing treatments
Mathieu Kielwasser Research and Development Composite / metal Joining - Challenges of Multi-material Joining
05
OUTLOOKS
Outlooks
The observation of current state of the art
Necessity to have several joining processes to ensure the joining feasibility
Necessity to use preparation before joining in same case
No choice between different kind of joining process to reduce the cost
Looking for
a universal joining process as spot welding for homogenous steel stack
processes that do not require any preparation
processes compatible with the large scale production

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When Metal meets Composite

Challenges of Multi-material Joining

Mathieu Kielwasser Rf. Doc. Info. : 01376_17_00198

1. Regulation Context, Issues and Target

2. Current Joining Processes

3. Challenges of Multi-material Joining

4. The Project Fast Lite Assemblage

Body Hang on parts

Material mix Material mix

Spot Welds (steel) 3578

Joining process Composite/Composite : adhesive bonding

EMP2 Platform Rear composite floor Metallic Insert

Introduced in bodyshop World premire

Protection part for lateral crash Woven Injected Door

Other studied joining processes

Composite with metallic insert Composite without metallic insert

Bodyshop process stand-by Cost reduction of composite part

Expensive composite part Introduction of new joining process(es)

Huge number of processes

FDS EJOWELDCFF EJOWELD RIVTAC RIVSET RIVSET HDX

RIVKLE SFC EJOT TSSD

Thickness limits of the sheet stack

Flow drilling limitation depending of Riveting limitation

Riveting limitation with standard rivet

Volume of the mechanical joining component

FDS Flow Drill

Need preparation : Pre-drilled hole

Ejotweld limitation Burns

Delamination and cut of the fabric

A response of all these defaults required several joining processes

FDS equipment Riveting die Clamping system Test equipment Floor

Academic partners Composite industry partners

The joining partners

Steering Committee Meeting

WP44 Assemblage de dmonstrateurs

Project startup J1 J2 End

Investment and running cost estimation

Composite / Composite Few joining solutions

Composite / Metal More joining solutions

Welding (Laser / US ...)

Necessity to have several joining processes to ensure the joining feasibility

Necessity to use preparation before joining in same case

No choice between different kind of joining process to reduce the cost

a universal joining process as spot welding for homogenous steel stack

processes that do not require any preparation

processes compatible with the large scale production

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