Professional Documents
Culture Documents
Michael Lough
Materials Engineering - JLR
GALM 2016
Confidential ©2016
Contents
• Who are JLR and what are its key business drivers
• What role advanced body materials have to play in answering
industry requirements
• Why is robust material development important
• Material approval processes
• Opportunities for continuous improvement
• Wrap up
2
JLR - Current Vehicles
• Land
Rover
Discovery
Sport
and
Range
Rover
Evoque
• c4,600
employees
• JD
Power
European
Gold
Plant
Award
2009
7
• Role Advanced Body Materials have to
play in answering industry requirements
Business Driver Material Requirement Solution
(Aluminium case study)
Performance Ø High specific strength material Ø 6xxx Post-Form Heat-
– Fun to drive solutions (right material right Treatment
place)
Ø High form for part integration
Drivers
Higher strength Al grades are required to:
• Lightweight the body structure by down-
gauging
• Replace requirements for Boron
reinforcements within body structure.
Objectives
Introduce new aluminium grade(s) that are:
• As high strength as possible
• Benchmark: Specific strength Boron
Steel
• Meet crash strength, corrosion and fatigue
Applications: Crash critical parts such as:
requirements
• Sill reinforcement
• Meet crash ductility requirements (including
consideration of non-tensile stress states) • Bumper reinforcement
• Compatible with current Design plus Joining, • B-pillar, A-pillar reinforcement
Paint and Adhesive (BOP/BOD)
What Next – Strength (Case study)
170°C / 30 min
Paint Bake
Low
Room Temp
Temp /
Time 170°C / 30 min
Paint Bake
Low
PERFORMANCE
MINIMUM
JLR’S EXPERIENCE WITH ALUMINUM
High Strength Grades
• Higher strength materials enable lightweighting via down gauging
• Generation III+ alloys have potential to compete with best steel
technology in strength critical parts
What Next – Formability 5xxx
To enable one-piece door inner: Benchmark:
Reduce radii
Increase re-draw
for pocket
Benchmark
Material = MS4
Range Rover Aluminium door inner - 5182 Evoque - steel door inner
Background Constraints:
Cost reduced Laser welding required – flange length limited
Rework decreased Fatigue – benchmark to 5182
Reduced part count
Ease of assembly (In house possible)
Weight savings
What Next – Formability 5xxx
Design proposal for full Aluminium
door solution
20
What Next – Formability 6xxx
Higher strength
skin grade to
enable down
gauging
Jaguar CX75
Bold Design
Crisp Lines
Statement
JLR’S EXPERIENCE WITH ALUMINUM
High Formability Skin Grades
• Background:
Left: AA6451
> Warranty associated with cosmetic, filiform
Below: AA6111
corrosion of Al skin panels
• Solution:
ALUMINIUM RECYCLING
Creating a closed loop
Enables lightweight automotive body
structures to be built using aluminium sheet
derived from low cost, energy efficient,
recycled sources.
£
Producing
Potential recycled
aluminium is
£5-10
million 95% less
energy intensive
save per than primary
year
• Challenges:
• Material Availability
• Volume – As usage of Aluminium increases in Automotive industry, sourcing of Aluminium
becomes more challenging.
• Global availability – Requirements for producing LWV on a global scale will increase
requirements for common aluminium grades in global market.
• Material Cost
• Volatile pricings linked though LME make forecasting vehicle costs very difficult.
• Aluminium treated as a technology not commodity which drives a lack of standardised approach
in grade development which leads to increased competition and cost increases.
• Potential Enablers:
• Increased availability of materials through common specifications
Materials
Development
Materials supplier / Logistics Manufacturing
- Storage Material developed for optimal
- Ageing performance in:
- Surface conditioning - Stamping / Manufacture
- Sustainability – production CO2 - Joining
- Supply route equivalence - Assembly
- Availability
27
An Introduction to Systems Engineering
successful systems.
Sub-System Sub-System
ctiona
I I
Successful systems must satisfy
the needs of their customers,
l targets
A “system” is a construct or
Integra
Design Optimisation
Robust Countermeasure
Development
29
Material Technology Delivery
2
Low Risk
1
Total Approximate
Category Comments
Score approval timing
A 14 – 18 Full Pre investigation, FMA study and materials characterisation required 18 months
0 1 2 3 4 5
Supplier/s fixed.
Material has been Production
Initial blue sky Material that is not Production route
risk assessed and material has been
idea – generally currently used by known.
benefits and supplied and
in research phase JLR and we have Material has gone
application characterised for
or with general limited Technology / through mass
understood. mass production
Description requirement understanding. requirements are
and vehicle
production trials
understood. and vehicle builds
Supplier chosen, development.
No fixed Supply base is not as required.
Process route is
production fixed, but options Draft material and
understood but Vehicle target
method or route. are considered. test specifications
location not fixed. confirmed
issued
Drivers Business case Pre Investigation Material Production trials
Characterisation
• Understanding of • Detailed benefit of • Initial test • Production trials
business need the technology results/ • Material • Materials
• Materials selection(s) • Identification of supplier data characterised approvals report
How to made potential suppliers • Full materials • Issue issued
• Risk score • DFMEA & Risk validation test specification
progress assessment plan • Confirmation of
between MRL • Initial test plan / • Confirm supply components
identification of route
required supplier • Issue draft
data specification
• Funding and
resource allocation
Material Readiness Levels
Limited
understanding of
material
Risk assessed
and benefits Production route
understood known and
technology Production material
supplied and
understood Mass production
Blue sky: research phase
characterised
trials complete
1 2 3 4 5 MRL
Produc?on
trials
Material
characterisa?on
Materials
approvals
report
issued
Ini?al
test
results
Issue
specifica?on
Full
materials
valida?on
Confirm
components
Production Trials
Understand
technology
test
plan
benefits
Material
Confirm
supply
route
FMA
and
risk
assessment
Issue
draH
specifica?on
Characterisation
Business
need
Ini?al
test
plan
Materials
Funding
and
resource
Pre-investigation
selec?on
Risk
score
Business Case
Drivers
• Ability of supply base to left shift (We need earlier engagement of material suppliers to
help develop materials of tomorrow).
• Reduction of long lead time testing…. Accelerate further accelerated testing (Adhesives,
Paints, Corrosion by understanding fundamentals.
• More applicable testing… .Greater focus is needed on developing test methods for
industry.
34
Conclusion
• JLR is a company that brings together two much loved and highly prestigious British car
brands
• Key business drivers for JLR include Design Quality, Performance, Capability,
• JLR utilises advanced body materials to deliver robust Light weight body structures. (Case