Development of Ultra Lightweight Parts Using Hot Stamping and Laser Welded Patchwork Technology

- Design Optimization of Patchwork Blank and Manufacturing Method Exploration-

Abstract

Hot stamping patchwork technology is gathering attention because it can achieve both crashworthiness performance and lightweight by locally increasing strength or thickness. In this study, an optimization method for determining the minimum patchwork blank was developed. Then it was applied to the design of patchwork structures of two hot-stamped parts, a hat-shaped part and a B pillar, and the effects of material strength and thickness on patchwork blank and lightweight were investigated. In addition, taking a hot-stamped hat-shaped part as an example, two manufacturing methods (arc welded overlay patchwork and laser welded patchwork) for realizing the optimized patchwork structure were examined through trial-manufacture, performance evaluation and feature comparison.