1. Steel Innovations in Hot Stamping
Paul Belanger
Director, Gestamp R&D North America

2. Organizational Approach Driving Innovation
R&D Centers
SPAIN
SWEDEN
FRANCE
GERMANY
JAPAN
BRAZIL
US
CHINA
INDIA

3. Hot Stamping Innovation History
1974 Objective: Replace cold stamping + batch hardening with forming/quenching
in one tool.

4. Hot Stamping Innovation History
Wear resistance
• Cutting knives
• Lawn mower knives
• Shovel blades
FIRST HARDENING LINE FIRST PRODUCTS

5. Hot Stamping Innovation History
Blanking
Austenizing
Forming & Quenching
Shotblasting
Key Attributes
• Formability as mild steel
• UHSS material data after hardening
• Yield strength/density ~ extruded Al
• Tight tolerances
• Good weldability
Collaboration with Luleå
University of Technology
1974-1979
• Process
• Tool
• Material
• Joining

6. Hot Stamping Innovation History
1983 First Automotive Product
• SAAB 9000: Side impact
beam, Front & Rear door

7. Hot Stamping Innovation History
Door
Beam
1%
FR/RR
Bumper
5%
Tunnel
X-MBR
Sill
9%
PH 1st Gen. [Uncoated]
PH
1G
18%
28%
50%
Local
38 %
FR
Rails
B-Pillar
A-Pillar
Upper
EVOLUTION OF PHS IN TERMS OF
TECHNOLOGY AND MATERIAL
Weight % of BIW possible
RR Rails
B-Pillar Local
Soft Zone

8. Hot Stamping Innovation History
Door
Beam
1%
FR/RR
Bumper
5%
Tunnel
X-MBR
Sill
9%
PH 1st Gen. [Uncoated]
PH
1G
18%
28%
50%
Local
38 %
FR
Rails
B-Pillar
A-Pillar
Upper
EVOLUTION OF PHS IN TERMS OF
TECHNOLOGY AND MATERIAL
Weight % of BIW possible
PH 2nd Gen. [Corrosion protection]
PH
2G
RR Rails
B-Pillar Local
Soft Zone
AlSi

9. Hot Stamping Innovation History
Door
Beam
1%
FR/RR
Bumper
5%
Tunnel
X-MBR
Sill
9%
PH 1st Gen. [Uncoated]
PH
1G
18%
28%
50%
Local
38 %
FR
Rails
B-Pillar
A-Pillar
Upper
EVOLUTION OF PHS IN TERMS OF
TECHNOLOGY AND MATERIAL
Weight % of BIW possible
PH 2nd Gen. [Corrosion protection]
PH
2G
PH
3G
PH 3rd Gen. [Softzone]
RR Rails
B-Pillar Local
Soft Zone
AlSi

10. Hot Stamping Innovation History
Door
Beam
1%
FR/RR
Bumper
5%
Tunnel
X-MBR
Sill
9%
PH 1st Gen. [Uncoated]
PH
1G
18%
28%
50%
Local
38 %
FR
Rails
B-Pillar
A-Pillar
Upper
RR Rails
B-Pillar Local
Soft Zone
EVOLUTION OF PHS IN TERMS OF
TECHNOLOGY AND MATERIAL
Weight % of BIW possible
PH 2nd Gen. [Corrosion protection]
PH
2G
AlSi
PH
3G
PH 3rd Gen. [Softzone]
PH
4G
PH 4th Gen. [Laser improved ]
PH
4G
PH
Process

11. Co-development examples
5 Technologies yielding 4 innovation products
NEW Zn Hot Stamping NEW extreme BODYSIDE
Remote Laser SeamWelding
PROCESS TECHNLOGY PRODUCT INNOVATION
In-Die Soft Zones
Flex Laser Soft Zones
3D LaserCladding (TPP)
NEW front rail LWT
NEW rear rail LWT
NEW B Pillar LWT
1
2
3
4
5
PROCESS TECHNOLOGY PRODUCT INNOVATION

12. Co-development examples
5 Technologies yielding 4 innovation products
NEW Zn Hot Stamping NEW Zn BODYSIDE
Remote Laser SeamWelding
PROCESS TECHNLOGY PRODUCT INNOVATION
In-Die Soft Zones
Flex Laser Soft Zones
3D LaserCladding (TPP)
NEW Front Rail LWT
NEW Rear Rail LWT
NEW B Pillar LWT
1
2
3
4
5
PROCESS TECHNOLOGY PRODUCT INNOVATION

13. Process Technology 1: Zn MSHc
Blanking Heating Stamping Laser
ALSI PROCESS EQUIPMENT (direct PHD process)
Hydraulic press
5 SPM
2-4 Blanks/stroke

14. Process Technology 1: Zn MSHc
Blanking Heating Stamping Laser
ALSI PROCESS EQUIPMENT (direct PHD process)
Hydraulic press
5 SPM
2-4 Blanks/stroke
Blanking Heating Stamping Shotblast
Zn PROCESS EQUIPMENT (direct MSHc, Multi-Step Hot Stamping Process*)
Technology Innovation Status:
- Zn without Microcracks ( <10µm)
- Steel modified to reduce forming start temp, enable mechanical transfer press
- Production ready ~2017-2018
910º C
Mech. transfer press
Multi-step operation
> 15 SPM
1-4 Blanks/stroke
Modified 22MnB5
* Patents Pending

15. Process Technology 1: Zn MSHc
 High speed centering & transfer system (OP05)
o Transfer system
 Press
o Servo transfer
o Cycle time = 15-up SPM
o Blanks per stroke = 1 – 4
o 3,000k S/a
 Tooling
o Max OP = 4 – 5
o Thermostabilized tools
OP05 OP10 to OP50
Transfer Press
1.800 Tn
2500x4500mm
SHOTBLAST
Zn MSHc (Multi-Step Hot Stamping Process*)
* Patents Pending

16. Process Technology 1: Zn MSHc
 Base material
 Similar post hot stamped mechanical properties to 22MnB5
 Increased formability vs. 22MnB5 at lower temperatures
 Zn-coating
 Offers cathodic protection
 Capable for direct hot stamping process
 Micro cracks < 10µm
 Hot Stamping process
 High productivity (target cycle time 2-3”)
 Furnace protective atmosphere not required
 Possibility to produce complex parts including negative angles
 Good weldability and savings using LWB (Ablation not required)
 No Laser cutting needed
 Tailored properties also possible!!
Zn Multi-Step Hot Stamping Process (MSHc*) Summary
* Patents Pending

17. Product Innovation 1: New Zn Bodyside
... with current multipart concept
…
… leads to TWB PH optimized Door Ring
…with Blank optimization
TWB TWB
TWB  Enhanced SOF performance
 Part number reduction
 Simplify Assembly Complexity
 Single stroke
 Cost reduction (no ablation)
 Mass saving
Increasing safety requirements…
4 parts
assembly
1 part

18. Process Technology 2: Remote Laser Seam Welding
Technology: Remote Laser Seam Welding
Laser welding: With seam tracking -continuous joint
along an edge or short flange
Benefit: Mass savings (reduced flanges) while
maintaining or improving energy absorption
A-Pillar
B-Pillar
Rocker
Application opportunities…
…on BIW structural parts
Front Rails
Rear Rail
Remote laser weld
 Reduced Flanges
Spotwelding
Laser Welding

19. Process Technology 2: Remote Laser Seam Welding
Press hardening Remote
Laser welded tube 
Continuity
Remote Laser
welding lines
Inner
Outer
Resistant welding
Laser
welding
• B-Pillar inner flange reduction • A-Pillar inner flange reduction

20. Process Technology 3: In-Die Soft Zones
• Technology: In-die partial hardening
 Tailored properties on hot stamped parts
 Controlled heating/cooling tool technology
 Benefits:
 Optional grades obtained: HT400, HT550
 Application freedom: Geometry and strength
 Wide areas feasibility
A-Pillar
B-Pillar
Front Rails
 Application opportunities…

21. Process Technology 3: In-Die Soft Zones
Soft flange on A pillar to improve weld ductility
• Material grade HT400
• Oblique pole crash test on vehicle
Side crash view from upper side
NEW VOLVO XC90 Soft flange

22. Process Technology 4: Flex Laser Soft Zones
Technology: HT700 Flex Laser
Obtain tailored properties
Material grades obtained: HT700, HT550, HT400
Narrow areas and complex patterns feasible
Application to low thicknesses [0.8 mm]
Rivet solutions to aluminum structures
Application opportunities…
…as combination with press hardened partsFront Rails
A-Pillar
B-Pillar
Rear Rail
HS WheelhousesHinge Pillar

23. Process Technology 4: Flex Laser Soft Zones
Innovative use of the technology: Advantages
Increased bending areas energy absorption
 Through higher range material
HT400 HT550 HT700
+19% abs.
+37% abs.
Energy abs.
+18%
+35%
Loading Capacity

24. Process Technology 4: Flex Laser Soft Zones
Innovative use of the technology: Advantages
Increased bending areas energy absorption
 Through higher range material…
 … combined with more flexible process
+33% abs.
+13% abs.
+9% abs.
321
Energy abs.Loading Capacity
+14%
+8%
+2%
Pattern NOK

25. Process Technology 5: 3D Laser Cladding (TPP)
Technology: Tailored Product-Process (TPP)
 Melt powdered metal with a laser
 Put material at the right place for
 Crash
 NVH
 Stiffness management
Applications
 Upper B-Pillar in Side crash
 A-Pillar in frontal SORB crash
Applications
 Lower B-Pillar in Side crash
 A-Pillar in Side Pole crash
Local
Intrusion
BendingMoment/
Force
Increase
Energy
Energy absorption
Intrusion
BendingMoment/
Force
Increase Loading capacity
Increase Stiffness
Structure sustainment (Buckle resistance)

26. Product Innovation 2: Front Rails
GESTAMP Current Best in Class
Press Hardening + SZ
Multiband
Flex Laser Soft Zone:
Decrease hat thickness
1,5mm1,1mm
Performances improvement
-11% weight saving
-25% weight saving
Product Innovation
PH + SZ Multiband
 Progressive force
increase
 Controlled bending mode
3D Laser Cladding -TPP:
Increase local stiffness/
buckle resistance
 Controlled kinematics with local SZ
 Increased stiffness with same
geometry
 Improved failure management
GESTAMP Future Best in Class
Press Hardening + SZ Multiband
& Laser applications
HT700
HT700
USIBOR+SZ
t. 1,1mm
USIBOR+SZ
t. 1,1 mm
-37% weight saving
Spot Welding  Remote Laser Seam Welding:
• Reduce flanges
• Create continuous joint
Future Best-In-Class
TechnologiesCold stamping
Baseline

27. Product Innovation 3: Rear Rails
GESTAMP Current Best in Class
Press Hardened + local SZ “snake”
PHS 1500 + SZ
t. 1,1mm PHS 1500
t. 1,0mm
HT400
HT400
PHS 1500 +SZ
t. 1,1mm
Product Innovation
PH + Local SZ “snake” design
 Controlled kinematics with local SZ
-11% weight saving
Cold stamping
Baseline
DP600
t. 1,4mm
DP780
t. 1,2mm
DP600
t. 1,4mm
DP600
t. 1,4mm
GESTAMP Future Best in Class
Press Hardened + local SZ
“snake” & Laser applications
PHS 1500
+SZ
t. 0,8mm
PHS 1500 +SZ
t. 0,8 mm
PHS 1500
t. 1,0mm
HT700
HT700
 Controlled kinematics with local SZ
 Increased stiffness with same
geometry
 Improved failure management
-30% weight
saving
Flex Laser Soft Zone:
Decrease hat thickness
1.1 mm0.8 mm
3D Laser Cladding -TPP:
Reduce patch size due
to TPP cladding
Spot Welding  Remote Laser Seam Welding:
• Reduce flanges
• Create continuous joint
Future Best-In-Class
Technologies

28. Product Innovation 3: Rear Rails
 20% weight saving
 Stability
 Efficiency
 Repeatability
 Complexity
 Single piece
 Patches not required for mode control/energy absorption
 Minimal spot weld count & reduce piece cost…
 Location, size, and properties of soft zones were developed using CAE
Top view
Side view
Bottom view
“Snake Design” Rear Rail - Horizontal bending control
3 1
2
1
2
3
Published by HONDA R&D America (GDIS Seminar 2015)
Co-development success example : Honda Rear rails Full vehicle Rear crash validation
FMVSS301 80km/h
Co-developed by GESTAMP R&D (G-Lab)

29. Product Innovation 4: B-Pillar
GESTAMP Current Best in Class
Cold stamping
Baseline
GESTAMP Future Best in Class
PHS 1500 Mono SZ + PHS reinforcement
& Laser applications
Performances improvement
-14% weight
saving
3D Laser -TPP
Increase top
stiffness
 Improve part
bending
Flex Laser Soft flanges
Create soft material locally
 Improvement of failure
management
3D Laser -TPP:
Reduce patch
due to laser
cladding
Remote Laser
Seam Welding:
Reduce flanges
PHS 15000 Mono SZ + PHS Reinforcement
Bending mode: local
Product Innovation
HT400 Soft
Zone
Cellar Design
Concept
Product Innovation
• Flex laser soft
flanges
• Improved failure
management
-27% weight
saving
Future
Best-In-Class
Technologies

30. Product Innovation 4: B-Pillar
Co-development success example : AUDI B-Pillar
 weight saving and fixation concept
 Smaller cross sections
 Connection hot formed B Pillar to
aluminum bodyside through hemming
 Soft zones in flanges to join with riveting
 Soft zone in lower B Pillar area to ensure
smooth crash kinematics
 Location, size, and properties of soft
zones were developed using CAE

31. Product Innovation Summary
 HT700 Soft Flanges
 Ultra thin PHS 1500,
t = 0.8mm
 TPP Opportunities
HS Wheelhouses
 HT700 Soft Zone
 HT700 Soft Flanges
 TPP
 Laser Remote
Technology
B-Pillar
A-Pillar
 HT700 Soft Flanges
 TPP
 Tubular Design with Laser
Remote Technology
Rear Rails
 HT700 Soft Zone
 TPP to increase stiffnes
 Laser Remote Technology
 TPP to increase
stiffness
 Deformation area
 Ultra thin PHS 1500
t = 0.8mm
 TPP Opportunities
Side Impact Beam
 RSW Failure
 RSW Failure
 Local Stiffness
 Controlled
deformation
(All HT grades available)
(All HT grades available)
(All HT grades
available)
 Improve Stiffness
1 piece
Body side
 TWB
 Cladd
 Ducti
 Improve Stiffness
 RSW Failure
 HT700 Soft Zones
 HT700 Soft Flanges
 Ultra thin PHS 1500
t = 0.8mm
 TPP Opportunities
Front Rails
 Controlled deformation

32. THANK YOUThank you