GM GMT900 Case Studies

GM GMT900 Case Studies
SUV Rad Support made out of
aluminum converted to
Pick-Up Rad support out of steel
Presented By: Bo Lindgren
VP Engineering
Pick-Up Steel
Radiator Support
• GM steel Rad-Support
production started in
2006
• Volume 600,000 to
1,000,000 /year
Product – Aluminum
Radiator Support
• Our initial order from
GM was an aluminum
rad support structure,
used in their full size
SUV vehicles
Challenge – Pick-Up
Steel Radiator Support
• Redesigned from aluminum to
steel
• Mass neutral (compared to
aluminum)
• High strength steel profiles
• Variable thickness material
• Higher load requirement
• Why? Cost savings
Laser-welded steel profiles
Inner and outer post
Upper and lower tie-bar
Lower Tie Bar
• Hot dip galvanized
• Variable thickness
material 1.9 to
1.0mm
• Dual phase
material
550 mpa
• 1640mm long
Variable Thickness Material
1.9 mm
1.0mm
1.9 mm
All features are done before welding
Embossing
Extrusion
Lower Tie-Bar weld seam
Early Options
Use a flange to create a
lap-weld
Final T joint
•Hot dip galvanized
•16 micron coating
•Laser beam from the
side
•Out-gassing from the
backside
•Galvanized
•Thickness
1.0mm
•Material HSLA
420 Mpa
•Profile formed
after welding
Upper Tie Bar
Upper Tie-Bar
• Material galvanized HSLA 420 material
with thickness of 1.0mm
Early Options
GMT 900 STEEL RAD SUPPORT
MANUFACTURING EQUIPMENT
Design of the part profile
Change
this area.
Weld
Early Options
Early Options
Early Options
Weld area
Final configuration for upper tie bar
Lap joint
Upper Tie bar
Laser cutting after welding and forming
Late design change
end tab feature
Upper tie-bar problems showing up
Material changing from uncoated to
galvanized
Inner post
• Uncoated material
• Material 1.0mm
thick
• HSLA material
420 Mpa
Inner post
The profile started
out with a
overlap in this area
for welding
Inner post
Final product
Butt Welding of inner and outer post
Outer Post
• Uncoated material
• Material 1.1 mm
thick
• HSLA material 420
Mpa
• Part manufactured
as a 2-up and
formed before
splitting
Outer Post
Part
manufactured as
a 2-up and
formed before
splitting
Thank you for your interest
Presented By: Bo Lindgren
VP Engineering
North American
Light Vehicle Metallic Material Trends
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