干货 | 激光拼焊板的优势

Laser welded blanks (LWBs) enable carmakers to reduce the weight of a monolithic part. At the same time, the strength or safety performance of the part can be maintained or improved, depending on the combination of steels selected.

通过不同的钢材组合，激光拼焊板(LWBs)能帮助汽车制造商减轻零件的重量，同时满足相同或者更高的强度以及安全性能。

Key advantages of LWBs include:

激光拼焊板的主要优势包括：

·Material optimization

·材料优化

·Improved technical performance without increasing weight

·在不增加重量的前提下改善技术性能

·Simplification of the OEM’s production processes

·简化整车厂的生产工艺

·Weight and thickness reductions for the complete assembly  

·减轻重量和厚度，降低装配难度

·Butt-joining to avoid overlaps

·采用对接焊，避免搭接

·Safety improvements

·提高安全性能

Material optimization 材料优化

During the blanking step, laser welded blank shapes can be arranged to make maximum use of the steel. Known as ‘nesting’, this technique increases the number of parts that can be made from one sheet of material. Less steel is required, and less scrap is produced.

通过在落料工序调整激光拼焊板的布局，可以最大限度地利用钢材。这种技术被称为“布料”，使用该技术，一张材料可以生产出更多的零件，用到的钢材更少，产生的废料也更少。

The right steel grade is in the right place, in the right thickness to create a tailor-made solution for each part.

我们在合适的位置采用合适的钢种和合适的厚度，为每个零件量身定做解决方案。

Depending on the shape, scrap rates can be as low as seven percent. With lower scrap rates, cost efficiency is increased significantly.

根据形状的不同，废品率可以降低至7%。随着废品率的降低，成本效率可以显著提高。

Nesting can lead to significant material savings depending on the shape of the parts to be blanked.

This compares very favorably to the scrap rate for monolithic parts which can be one third or higher.

根据零件的形状不同，通过布料可以节省大量的材料。

下面这个案例很好地反映出：单一料片方案比激光拼焊板方案的废品率高出三分之一或者更高。

More than one-third of the coil can be scrapped if monolithic blanks are utilized

如果采用的是单料片方案，钢卷的三分之一都将成为废料

ArcelorMittal Tailored Blanks (and GONVVAMA in China) can work with an OEM’s design department to determine if a part is suitable for nesting. The assessment includes an assessment of the technical requirements for the part and a cost analysis to achieve the most economical solution.

安赛乐米塔尔拼焊板AMTB（在中国为GONVVAMA）可以同整车厂的设计部门合作，确定零件是否适合采用布料的方式，并对零件技术要求和成本等进行评估，从而找出最经济的解决方案。

Improved technical performance without increasing weight

在不增加重量的前提下改善技术性能

Using LWBs, the technical performance of a part can be enhanced significantly without adding to the weight of the vehicle. 

在不增加车辆重量的前提下，采用激光拼焊板可以显著提高零件的技术性能。

Examples of improved technical characteristics include:

改进技术特性的例子包括:

·    Higher stiffness 刚度更高

·    Better energy absorption 更好地吸收能量

·    Improved crash behavior 抗碰撞表现更好

Simplification of the OEM's production processes

简化整车厂的生产工艺

OEMs can simplify their production processes with LWBs thanks to:

整车厂可通过激光拼焊板简化他们的生产工艺，因为：

·    Reduced number of parts

·    零件数量减少

·    Reduction in the number of stamping and assembly tools required

·    所需冲压次数和工装数量减少

·    Shorter manufacturing process

·    生产流程变短

Weight and thickness reductions for the complete assembly

降低重量和厚度，减轻组装难度

LWBs are a clever way to significantly reduce the mass of a part or the body-in-white of a vehicle. Thanks to the very high strength of modern automotive steels, very thin gauges can be utilized. Using some of the most advanced high strength steels, weight savings of 10 to 20 percent (or more) can be achieved for a single part.

激光拼焊板可以显著降低白车身的重量。由于现代汽车用钢具有很高的强度，因此可以使用非常薄的规格。使用一些最先进的高强度钢，一个零件可以节省10%到20%(或更多)的重量。

The weight savings occur because 重量减轻是因为:

·  The thickness of the steel used in a LWB part can be optimized to eliminate unnecessary weight.

·   激光拼焊板零件可以优化钢材厚度分配，减少不必要的重量。

·   The steel blanks are butt joined. Overlaps are reduced to a minimum, cutting weight significantly.

·   钢板采用对接焊，重叠部分减少到最小，从而显著减轻重量

By ensuring the right material is in the right place, in the right thickness, LWBs can significantly reduce the weight of a part.

通过确保在正确的位置使用正确的材料、正确的厚度，激光拼焊板可以显著降低零件的重量。

The following image shows the example of a door ring. The LWB solution on the right can be up to 20 percent lighter than the multi-part door assembly shown on the left.

下图为门环案例。右边的激光拼焊板解决方案比左边的多零件门框组合轻20%。

By optimizing the thickness of each blank, the weight of a component can be reduced significantly

通过优化每一块板料的厚度，可以显著降低零件重量

Case: Honda's Acura MDX features world-first single-piece door ring

案例：本田讴歌MDX，世界上第一个一体成型门环

Butt-joining to avoid overlaps

采用对接焊，避免搭接

In traditional vehicle assembly, different parts were overlapped to ensure a strong join. With LWBs, overlaps are eliminated in many parts. Instead, the two parts are butt welded, reducing the amount of material used and the overall weight of the part. When combined with thickness optimization, excellent weight savings can be achieved.

在传统的汽车装配中，为了保证高强度连接，需要对不同的零件进行搭接。但是激光拼焊板则可以对两个零件进行对接，降低材料利用率和零件的整体重量。再加上厚度优化，重量可以得到大大减轻。

By butt joining blanks, the additional weight of overlaps is eliminated

通过板料对接去掉了重叠部分的额外重量

Safety improvements

提高安全性能

The development of LWBs has had a direct impact on improving automobile safety since they were first introduced in the 1990s. This is because LWBs combine the energy absorption and anti-intrusion properties of different grades of steel in one part.

自20世纪90年代激光拼焊板问世以来，其发展对提高汽车安全性产生了直接影响。这是因为激光拼焊板将不同等级钢种的能量吸收性能和抗撞击性能结合在了一起。

Evolution of LWB use:

激光拼焊板应用的演变：

·    In the 1990s, most vehicles on the road in Europe had a two-star Euro NCAP safety rating. The average vehicle included two LWB parts and comprised five percent advanced high strength steel (AHSS).

·    在上世纪90年代，欧洲道路上行驶的大多数汽车在欧洲NCAP安全评级中得到二星。每辆车平均包括两个激光拼焊板零件和5%的先进高强度钢(AHSS)。

·    During the 2000s, the first vehicle to achieve a five-star Euro NCAP rating included 22 LWB parts and was comprised of 45 percent AHSS.

·    在本世纪初，第一个获得欧洲NCAP五星级评级的汽车包括22个激光拼焊零件，其中45%是先进高强钢。

·    During the 2010s, the combination of LWB and hot stamping has further reduced the weight and cost of vehicles, and improved safety significantly. Of the 69 Euro NCAP ratings published in 2017, 44 vehicles (64 percent) achieved a five-star rating.

·    2010年以来，激光拼焊与热冲压技术的结合进一步降低了车身的重量和成本，大大提高了安全性。在2017年公布的69个欧洲NCAP评级中，有44款车(64%)获得了五星评级。

·    ArcelorMittal’s S-in motion^® studies have demonstrated the safety benefits and weight savings LWBs can provide in today’s production vehicles.

·    安赛乐米塔尔(ArcelorMittal)的S-in motion®解决方案充分展示了激光拼焊板给今天的汽车设计带来的安全性能的提升和重量降低。

Example: Improved crash performance with hot stamped LWB door ring

案例：热成型激光拼焊门环改善了抗碰撞性能

A new front and side body structure was designed to meet frontal small overlap crash requirements.

设计了一种新的前、侧车身结构，以满足正面小重叠碰撞的要求。

Example: Improved crash performance with hot stamped LWB door ring

案例：热成型激光拼焊门环改善了抗碰撞性能

Optimized laser welded blank shotgun solution with several Dual Phase steel grades leads to best compromise to cope with all frontal crash tests

优化的采用双相钢的激光拼焊手枪板能够应对所有的正面碰撞测试

来源 Source：https://automotive.arcelormittal.com/LWB_advantagesor