COLOGNE, Germany, Oct. 31, 2018 – Once it was a technique that helped protect knights in armour from the crashing blows of their rivals. Now, Ford is applying a cutting-edge version of the same technology to help make its cars safer than ever.
The first fully automated hot-forming process shapes and cuts parts of the car – which are integral to protecting drivers and passengers – using giant furnaces, robots and 3,000° C lasers.
“We are building on techniques used to strengthen steel for thousands of years, incorporating modern materials and automation to speed and refine the hot-forming process,” said Dale Wishnousky, vice president, Manufacturing, Ford of Europe. “The resulting boron steel safety cell helps to make the all-new Focus one of our safest vehicles ever.”
The hot-forming line – fully integrated within the company’s Saarlouis Vehicle Assembly Plant in Germany – was built as part of a recent €600 million investment in the Saarlouis facility. Hot forming is an integral part of the production of the all-new Ford Focus that was awarded a maximum five-star Euro NCAP safety rating.
All-new Focus makes extensive use of boron steel – the strongest steel used in the auto industry – within the car’s safety cell. This helps to create a survival space in the event of an accident. In addition, the use of boron, also found in skyscrapers, helps the new model to achieve a 40 per cent improvement in the car’s capability to withstand head‑on crashes.
Hot-formed steel pieces are subjected to temperatures of up to 930° C; unloaded by robots into a hydraulic press that has a closing force up to 1,150 tonnes; and then shaped and cooled in just three seconds. The boron steel is so strong by this point that a laser beam hotter than lava is used to precision-cut each piece into its final shape.
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About Ford Motor Company
Ford Motor Company is a global company based in Dearborn, Michigan. The company designs, manufactures, markets and services a full line of Ford cars, trucks, SUVs, electrified vehicles and Lincoln luxury vehicles, provides financial services through Ford Motor Credit Company and is pursuing leadership positions in electrification, autonomous vehicles and mobility solutions. Ford employs approximately 200,000 people worldwide. For more information regarding Ford, its products and Ford Motor Credit Company, please visit www.corporate.ford.com.
Ford of Europe is responsible for producing, selling and servicing Ford brand vehicles in 50 individual markets and employs approximately 53,000 employees at its wholly owned facilities and approximately 68,000 people when joint ventures and unconsolidated businesses are included. In addition to Ford Motor Credit Company, Ford Europe operations include Ford Customer Service Division and 24 manufacturing facilities (16 wholly owned or consolidated joint venture facilities and eight unconsolidated joint venture facilities). The first Ford cars were shipped to Europe in 1903 – the same year Ford Motor Company was founded. European production started in 1911.
