BMW

Group

Technological Innovations in Body in

White Manufacturing of the BMW X6

Markus Pfestorf
BMW Group
Duane Copeland
BMW MC

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BMW Content
Group

Body in White Requirements for EfficientDynamics

Body in White Materials

Ultra High Strength Steel Grades

Joining Technologies

Conclusion

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BMW Body in White Requirements
Group
Efficient Dynamics

Body
In
White

Pow
er T x le and
rain A
em atics
Kin
EfficientDynamics
W ad
cs

Lo
eig Di
mi

ht stri
na

an bu
dy

d tio
ro

Ax n
Ae

le

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BMW Body in White Requirements
Group
Cost Efficient Light Weight Design

Specific Panels
Shared Panels

- Torsional Stiffness of 29.000Nm/

- Implementation of Ultra High Strength Steel Grades
- Mixed Material Concept (Steel, Aluminum, Thermoplastic)
- Cost Efficient Engineering using existing Panels with a maximum Design
Differentiation

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BMW Body in White Materials
Group
Yield Strength

180 MPa 200-220 MPa, 4 %

15%
260 MPa
7%
Deep Drawn Steel
14%

300 MPa
18%
Others, 4%
6xxx Aluminum, 2%

950 MPa, 3%
680 MPa, 5% 380-420 MPa, 25%
550 MPa, 3%

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BMW Body-In-White Materials
Group
Average Minimum Yield Strength

500
475
MPa
Average min. Yield Strength Rp0,2

400

350

300

3Series
3Series Sedan
3Series Sports W.
Current X5

1Series
?X6
3Series Coup

6Series Convertible
250 Sports Wagon 7Series
5Series
6Series Coup
3Series
5Series Sedan 5Series Z4Coup
Z4 Sports Wagon
200 Previous X5
3Series
3Series Compact
7Series 5Series Coup
Sports Wagon 3Series
150 Convertible

1994 1996 1998 2000 2002 2004 2006 2008 2010

Start of Production

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BMW Body-In-White Materials
Group
Average Thickness

1,7

mm
3Series Convertible

1,5

1,4 Without Z4
Advanced
High Strength Steel
Average Thickness

6Series Convertible
1,3 Current X5
6Series Coup
X6

1,2 Previous X5
3Series Sports Wagon

7Series
1,1 5Series Sports Wagon

5Series 1Series
1,0 7Series

0,9
1992 1994 1996 1998 2000 2002 2004 2006 2008 2010
Start of Production

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BMW UHSS Hot Stamped 22MnB5
Group
Side Crash
Thickness (t)
t = 1.2 mm

t = 2.2 mm

Weight Savings: 2 kg/side

t = 1.4 mm (compared to a hot stamped part
with a constant thickness)

Mechanical Values:
t = 1.2 mm Yield Strength Rp0,2: > 950 MPa
Tensile Strength Rm: > 1300 MPa

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BMW UHSS CP800
Group
Rear Crash

Weight Savings for the

Longitudinal Rear Member:
4,4 kg

Mechanical Values:
Yield Strength Rp0,2: 680 - 830 MPa
Tensile Strength Rm: 800 - 980 MPa
Elongation A80: > 10%
(Complete Longitudinal rear member
including other steel grades)

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BMW UHSS CP800
Group
Rear Crash of a Prototype

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BMW UHSS CP800
Group
Rear Crash
118 mm
Mech. Properties Mech. Properties
(as delivered) (180C, 60 min.)

88 mm
Yield Strength Rp0,2 692 MPa 796 MPa
Tensile Strength Rm 901 MPa 923 MPa
Elong. after Fracture A80 11,4 10,8
Thickness 0,99 0,99

200
Tested profile
157,37 kN (with Bake Hardening Response)
kN
155,84 kN (without Bake Hardening Response)
Deformation Force

120

80

40

Deformation Time Specimen after Drop Test

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BMW UHSS CP800
Group
X6 Part Application

Thickness of all Parts: 1,5 mm

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BMW UHSS CP800
Group
Tool Realization Guidelines

a a
b

Phase 1 Phase 2 c Phase 3

Tool Change Content : a) Optimize the release of flange form

b) Optimize the draw of the embossments
c) Increase the radii if necessary
d) Optimize the trim

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BMW UHSS CP800
Group
Clamping in Body in White

Secure the part fastening assembly process in the Prototype Phase.

Testing the Series assembly Tools with the Prototype Parts and early
Optimization of the Clamping Technology.
Higher Measurement Stability in the BIW.

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BMW Joining Technologies
Group
Materials and Joining Technologies

Main Joining Technologies:

Resistant Spot Welding (6643 Spot Welds)
Adhesive Bonding (116999 mm)

Spot Weld Other Joining Technologies:

Self Pierce Riveting (82)
Clinching (53)
Mig Welding and Brazing (8053 mm)
Capacitance Discharge Welding

Adhesive Bonding

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BMW Joining Technologies
Group
Benefit of Structural Adhesives
Local Static Stiffness
+ 12%
Upper Control Arm
Static Torsional Stiffness + 2%
+ 0.1Hz
Dynamic Stiffness to
+ 0.3Hz
Applied Adhesives Benefit on Stiffness

with Adhesive
without Adhesive

Local Static Transversal Stiffness of Difference of Displacements of the

the Upper Control Arm Spring Support with and without Adhesive
Application

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BMW Joining Technologies
Group
Aluminum Casted Front Shock Tower
Supplier Body In White Paint Shop

- High Pressure Vaccum - Bonding (ca. 5.4 m) - PVC Sealant

Casting
- Self Pierce Rivets (82
- Heat Treated times)
- Machined
- Cataphoretic Painting

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BMW Joining Technologies
Group
Capacitance Discharge Welder
Cold Forged part
Material: C15E2C

52 mm

90 mm
Advantages:
- More economical Process
- Less Weld Splatter
- High local connection Stiffness
- Smaller amount of Heat introduced in Parts during
the welding Process
- No Process induced Material Structure Change.

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BMW Joining Technologies
Group
Capacitance Discharge Welder

1
1,0 mm
Force (kN)

Distance (mm)
200 m
Force vs. Distance Relationships: Internal Weld Seam Evaluation:
1 Outer projection - Small Fusion Zone
2 Inner projection - Small heat induced Zone
- Continuous Material Connection

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BMW Conclusion
Group

Mixed Material light weight Concept for the Body in White

8% Ultra High Strength Steel Grade
46% Advanced High Strength Steel Grade

Significant Weight Savings by UHSS

Hot Formed B- Pillar Reinforcement with tailor rolled Blank
CP800 for Longitudinal Rear Member

Capacitance Discharge Welding for Bushings

High local stiffness
Extreme short Process Time

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BMW
Group

Thank You for Your Attention

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