MaX by aperam LEARN MORE

Meet MaX:

 

New technologies, new regulations and new expectations require car manufacturers to think outside the box. As a result, a new generation of vehicles is demanding new material solutions to reduce weight, improve safety, cut emissions and lower costs.

To meet this demand, Aperam introduces MaX – the market’s only Advanced High Strength Stainless Steel for body in white and chassis applications.

 

The MaX Offer

automotive manufacturers

MaX is available in three grades: MaX1.2HY, MaX1.6 and MaX HSHE (High Strength High Elongation). MaX1.2HY and MaX1.6 are currently being tested by our partners and customers, while MaX HSHE will be available for trials starting in 2019.

MaX1.6 and MaX1.2HY are ferritic stainless steels that, after thermal treatment, achieve a martensite phase, thus giving them an extremely high strength (until 1 600 MPa). Customers are already testing and qualifying this cost-effective material for reducing the weight of targeted parts.

MaX-imum Advantages

As an ultra-high strength steel formed by hot stamping, MaX has the lightweight performance of aluminium and the cost-effectiveness of carbon steel. As a result, it offers such advantages as:

  • Weight Reduction: With MaX, manufactures go from working with 24 different parts to just three – all while maintaining the same properties. This results in a significant reduction in weight – by up to 15%.
  • Cuts Costs: MaX’s simplified production process can cut investment costs by up to 75%. In dollars, this means a manufacturer can reduce investment costs from 1 million to just 250,000 dollars. This is a significant reduction and a key benefit that only MaX offers.
  • Better Performance: In terms of fatigue performance, MaX matches baseline measurements, and for crash resistance, MaX outperforms baseline measurements. Furthermore, its crash resistance is compliant with both US and EU standards.

Crash: MaX exceeds baseline measurements

Front crash - ODB 40 %

front crash

Side crash - Oblique Pole

Baseline

Baseline

MaX solution

MaX solution

MaX redefines how to design a vehicle’s under body, resulting in a better crash performance and maintaining NVH versus baseline measurements.

NVH: MaX maintains baseline level

NVH: MaX maintains baseline level

MaX - Torsion Mode = 50 Hz

MaX - Torsion Mode

MaX - Static Torsion = 21.9 kNm/°

MaX - Static Torsion

Innovation

  • Body in MaX
  • Dashboard
  • Front floor
  • Rear floor

Using stainless steel applications in body in white is a novel idea,
and Aperam is the first to offer this innovative solution
for the dashboard, front floor and rear floor.

front crash

Baseline

19 parts - 40.1kg

Baseline

MaX

3 parts - 34.6kg

MaX

-14%

weight reduction

reduction in thickness
and the number of parts

+0%

equivalent cost

price of parts manufactured
is equivalent

-25%

manufacturing steps

-25% welding spots

-75%

investment

MaX’s simplified production process
can cut investment costs

Dashboard

Dashboard + reinforcement integration

From 6 parts to 1 using patch technology

Dashboard + reinforcement integration

Baseline

6 parts - 10.7kg

Baseline

MaX

1 parts - 9.7kg

MaX
-9%

-9%

crashtestCrash simulation

Baseline

Baseline

MaX

MaX

Thanks to the enhanced crashworthiness of MaX, one can reduce the thickness of the dashboard and decrease intrusions into the safety cage during an ODB front crash. Due to its excellent formability, local reinforcements of the baseline are directly integrated into the dashboard panel as a patch. Thus, packaging constraints in the baseline are eliminated and the position of the patch is improved, resulting in an even further reduction in intrusions.

FeasabilityFeasability

Baseline
MaX

The dash panel is completed in two steps. The first step involves cold stamping, which assures the tunnel area. Next, the part is stamped in a hot stamping die with movable pads. This process becomes a hybrid of indirect and direct press hardening.

Front floor

Right and Left + tunnel integration

From 7 parts to 1 using TWB technology

Right and Left + tunnel integration

Baseline

7 parts - 17.8kg

Baseline

MaX

1 parts - 15.4kg

MaX
-9%

-14%

crashtestCrash simulation

Baseline

Baseline

MaX

MaX

Although not traditionally an energy absorbing part during a crash, using MaX in the front floor panel improves side pole crash performance while also reducing the overall thickness of the floor. With MaX, the entire floor panel is active during a crash: an increase in the stiffness of the tunnel means a more evenly distributed impact in the floor, resulting in lower intrusions on the side.

FeasabilityFeasability

Baseline
MaX

More and more manufacturers are using hot stamping parts. We propose the innovative concept of joining a low thickness part and a TWB. By taking advantage of reinforcement integration, one only has to produce one part.

Rear floor

Rear floor + spare wheel housing integration

From 6 parts to 1 using TWB technology

Rear floor + spare wheel housing integration

Baseline

6 parts - 11.6kg

Baseline

MaX

1 parts - 9.5kg

MaX
-9%

-18%

crashtestCrash simulation

Baseline

Baseline

MaX

MaX

MaX’s excellent properties allow for the use of thin panels and the integration of all reinforcements into a single part. As a result, not only are rear crash requirements fully met, the overall weight is also reduced. Despite its slender size, the floor helps absorb energy during a crash, allowing the fuel tank to remain intact.

FeasabilityFeasability

Feasability

The part can be stamped in a die using multiple movable pads, to be drawn in a certain sequence. The market uses a single die on current hot stamping lines for this process.

Partnership

 

Aperam developed MaX by working directly with car manufacturers, which allowed us to understand their challenges and create a solution that satisfies actual application needs.
To produce MaX, Aperam partners with a number of market-leading companies, including simulator, welding and component specialists.

 
Altair

Crash and NVH simulations,
structural optimisation

Bertrandt

Costing

conex Engineering

Prototypes and feasibility

Schuler

Feasibility and real industrial trials

oerlikon

Feasibility analysis

MA

Real industrial trials

More about MaX,

Charting New Roads
to Cost and Weight Reduction

The evolution of materials in the body in white is a reality and changes are happening fast. With the new MaX family grades, Aperam is prepared to drive this future by meeting the evolving needs of today’s automobile manufacturers.

To learn more, contact us today!

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