The Body in White of the new BMW 5 Series Gran Turismo.

Duane Copeland
BMW AG

Markus Pfestorf
BMW AG

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Contents

I) Introduction II) Concept of the Car III) Materials and Manufacturing Technologies

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Introduction

Coupe-Like Exterior Personal Space

Semi Command Position Perfect Entry Rear Leg Room Sedan-like Separated Trunk Panoramic Roof Coupe-Like Silhouette Frameless Doors High-Quality Appearance of Exterior (ex. chrome and high gloss black elements)

Functionality Modern, Elegant Interior

- New Type of High-Quality Interior - Extended Ambient Light - Single Rear Seat Configuration (option) - Twin-Trunk Lid - Trunk Volume - Flexible 2nd Seat Row / Trunk Size

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Relative Product Dimensions

1678 1456 1555

2933

3070

3070

BMW X6 BMW 7 series BMW 5 series Gran Turismo

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Technical Components for EficientDynamics

Integral-V-Multilink Suspension

Lower CO2 Emissions

Efficient TwinPower Turbo Engines

Runflat Tires Eight Gear Automatic Transmission with Steptronic Double-Wishbone Front Axle Light Weight Body in White Design

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Torsional Stiffness and Lightweight Coefficient

40.000 Nm/ 30.000 25.000
Torsional stiffness cT

4,0 31,500 3.0 2.6 27,500 3,5

cT

3,0
Lightweight coefficient L

2,5 2,0

20.000
15.000

1,5

10.000 5.000 0 mGer CT x A Closed Roof Sun Roof L mGer. cT A

1,0 0,5 0

L=

Kg Nm/x m

x 10 ]

Lightweight Coefficient Weight of Body-in-White Torsional Stiffness Area (wheel base x track width)

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Increase of Stiffness in the Front and Rear End

High Pressure Cast Aluminum Shock Tower

Struts Aluminum Struts

Torsion Frame Steel Aluminum

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Passive Safety
Driving Warning Correction Crash Unavoidable Active safety Stiffness Crash Post Crash Passive safety Strength

cT

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Load Path of Side Impact

B-Pillar

Impact

Hot Stamped Components

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USNCAP Barrier
Passenger Values OK Doors Remain Closed

Barrier Weight = 1368 kg

8 Cylinder 4-Wheel Drive (incl. simulated luggage) Load = 2555 kg

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Materials
Steel DC04 DX54D DX56D HC180BD, HC180YD HC220BD, HC220YD HC260BD, HC260LAD, HC260X(D) HC300BD, HC300LAD, HC300X HC340LAD, HC340X(D) HC380LAD HC400T HC420LAD, HC450X HC600C, HD680C HC700X HC1000W (+TE), HC1000WD+ZF
Aluminium

AlMg3,5Mn AlMg4,5Mn0,4 AlMg1/AlMg5,7/AlMg1 AlMg0,4Si1,2 AlSi0,6Mg0,5 AlSi10MgMnFe AlMgSi Others Other metallic materials

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Materials of the Structure

180 MPA 7% Deep Drawn Steel 19% 200 220 MPa 9%

260 MPa 10%

Others 5%
AlSi Aluminum 2%

300 - 340 MPa 21%

1000 MPa 12% 600 - 700 MPa 1% 380 - 450 MPa 14%

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Weight Savings Compared to Conventional Steel Grades

Hot Stamped Parts: -20,7 kg

Tail Gate: -13,2 kg

Shock Tower: -4,0 kg

Hood: -7 kg Doors: -16 kg

Total weight savings due to lightweight material design: 60,9 kg

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Hot Stamped Parts

B-Pillar Reinforcement Material: HC1000WD+ZF Thickness 1,80 A-Pillar Reinforcement Material: HC1000W Thickness 1,60 B-Pillar Reinforcement Inner Material: HC1000W Thickness 1,60 Longitudinal Side Member Inner Material: HC1000WD+ZF Thickness 1,50 Hinge Carrier Reinforcement Material: HC1000WD+ZF Thickness 1,60

Longituidinal Side Member Outer Material: HC1000WD+ZF Thickness 1,00

Tunnel Reinforcement Material: HC1000W+TE Thickness: 1,50

Uncoated Material Zinc Coated Material

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Press Hardening Process for Zinc Coated Boron Steel

Hot dipped galvanized coil

Cold forming

Austenizing + press hardening

Annealing (optional)

Cleaning (optional)

Oiling (optional)

1. Form and Trim in a conventional cold forming process.

2. Heat up the part to Austenitizing Temperature. 3. Pressharden by Quenching in a cooled die. 4. Cleaning of the parts to remove Oxide Layer (optional).

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Press Hardening Process for Zinc coated Boron Steel

Film

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Press Hardening Process Window

Increase of Oxide Layer

min. Time for Mechanical Properties

(austenitization of the material)

Process Window

max. Time for Welding Corrosion Protection Paint Adhesion Glue Adhesion
(Oxide layer and Fe content)

Oxide Layer Zn Fe Coating

Basic Material

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Barrier and Cathodic Protection

A. Overview Picture: Zinc Coated Hot Formed Steel after 10 weeks of testing B. Region along the Scratch: Cathodic Protection No Base Material Corrosion Corrosion Creep of Paint: 0,4mm C. Undamaged Region: Barrier and Cathodic Protection

100m Iron Zinc

Zn Fe Coating 22MnB5 Conclusion:

50m

Protection exists even with damaged surface and along cut edges Application in wet areas without supplementary support

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Coating Properties Zinc Distribution

22MnB5

Zn-FeLayer

10m

10m

Zinc-, Iron- Distribution

Conclusion: no zinc within the base material no Embrittlement of grain boundaries by zinc
Zn-Fe Layer 22MnB5

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Other Applications of Zinc Coated Boron Steel

BMW 7 series (SOP 2008)

BMW 5 series (SOP 2010)

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Application of Dual Phase Steel

Steel Grades HC260XD HC300X HC340X(D) HC400T HC450X HC600C, HD680C

Dachrahmen innen hinten an Serienstand angepasst 14.09.09

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Work Hardening of Dual Phase Steel (HC450X)

Thinning
min.

Specimen

2
max.

Measured Yield Strength Bent Part Deep Drawn Part

Section 1 548 MPa 767 MPa

Section 2 557 MPa 580 MPa

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Thank You for Your Attention

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