USAMP Low-Cost Mg Sheet Component Development and Demonstration Project

Technical Report · Tue Oct 19 04:00:00 EDT 2021

DOI:https://doi.org/10.2172/1827733· OSTI ID:1827733

Gerken, Randy ^[1]; Sachdev, Anil ^[2]; Ghaffari, Bita ^[3]; Adam, Aslam ^[4]; Hector, Lou ^[2]; Carter, Jon ^[5]; Mehta, Manish ^[5]

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1. Stellantis, Hoofddorp (Netherlands); USAMP c/o Bucciero & Associates
2. General Motors LLC, Detroit, MI (United States)
3. Ford Motor Company, Detroit, MI (United States)
4. Stellantis, Hoofddorp (Netherlands)
5. M-Tech International LLC, Ann Arbor, MI (United States)

The overarching objective of this USAMP project was to develop and demonstrate door panels made from magnesium (Mg) sheet with a cost penalty over conventional steel stampings of no more than $$\$$5.50$/kg saved. The technical approach integrated experiments with advanced computational tools based on Integrated Computational Materials Engineering (ICME) methods to develop new alloy chemistries and their thermomechanical processing that promise improved formability and lower forming temperatures. A penultimate task before finally forming the stampings was to incorporate actual microstructure into models that would enable formability simulations. This approach would, for the first time, account for individual magnesium grains moving in an anisotropic fashion unlike that for aluminum or steel that have isotropic properties upon which the current simulation tools are based. In separate activities, new coatings and lubricants to facilitate forming and improved corrosion protection and joining strategies, were developed to ensure that the door could be produced with stated product requirements. A technical cost model, which included parts production, assembly, and paint for a door specifically designed for Mg sheet, showed the cost penalty to be between $$\$$4.26$ to $$\$$6.60$/kg saved, which enveloped the project’s cost targets. The cost of the coated Mg sheet was identified as the key driver for the cost penalty. The mass of the Mg-intensive door was 7.9 kg, which was 54% less than the baseline steel door.

• Research Organization: United States Automotive Materials Partnership LLC (USAMP), Southfield, MI (United States)
• Sponsoring Organization: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Transportation Office. Vehicle Technologies Office
• Contributing Organization: USCAR LLC
• DOE Contract Number: EE0007756
• OSTI ID: 1827733
• Report Number(s): DOEUSAMP-7756-1
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
Alloy
Automotive
Coating
Coil
Constitutive Model
Corrosion Protection
Crystal Plasticity
Deformation
Door Panel
EBSD
Formability
Forming Limit Curve
ICME
Joining
Laser Welding
Lightweight
Lubricants
Magnesium
Manufacturing
Mechanical Testing
Multi-Material
Plating
Predictive Modeling
Pretreatment
Resistance Spot Welding
Rolling
Sheet
Simulation
Texture
Twinning
Warm Stamping