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Transcript of Reinventing Automotive Steel - California Air Resources · PDF fileReinventing Automotive...

  • Reinventing Automotive Steel

    California ARB Lightweighting Workshop May 18, 2010

    Jody Shaw - U. S. Steelwww.worldautosteel.org 2

    WorldAutoSteel

    automotive group of the worldsteel

    Ansteel Hyundai-Steel SumitomoArcelorMittal Kobe ThyssenKruppBaosteel Nippon Steel USIMINASChina Steel NUCOR U. S. SteelCorus-Tata POSCO voestalpineJFE Severstal

    www.worldautosteel.org 3

    AISI Steel Market Development Institute

    Partner Funding$6, 627,000

    68%

    Automotive Applications CouncilAK Steel

    ArcelorMittal Dofasco

    ArcelorMittal USA

    Nucor Corporation

    Severstal North America

    United States Steel Corporation

    www.worldautosteel.org 4

    Past steel projects and impact on vehicle structures

    Future Steel Vehicle - The new drivers of materials selection- New capability of steel.- Objectives- Performance criteria- Design methodology- Preliminary results

    Todays Presentation

  • www.worldautosteel.org 5

    ULSABUltraLight Steel Auto Body

    ULSASUltraLightSteel Auto Suspensions

    ULSAB -AVCAdvanced VehicleConcepts

    www.worldautosteel.org

    ULSACUltraLight Steel Auto Closures

    Steel Industry Investment in Automotive Lightweighting

    More than

    $60 Million

    www.worldautosteel.org 6

    70

    60

    50

    40

    30

    20

    10

    0

    Elo

    ngat

    ion

    (%)

    0 200 400 600 800 1000 1200 1400 1600 1800 2000Tensile Strength (MPa)

    Mart

    DP, CP

    TRIP

    HSLA

    CMnBH

    IF -HSIF

    Mild

    Automotive Steel Grades

    Steel Industry Investment in Automotive Lightweighting

    www.worldautosteel.org 7

    22% to 32% Weight Reduction

    Source: Auto/Steel Partnership

    Lightweight Front End Structures - 32% mass reduction - At no additional cost

    Future Generation Passenger Compartment-30% mass reduction - Improved crash performance- At no additional cost

    Lightweight Rear Chassis - 24% Mass reduction - At no additional cost

    Lightweight Closures- 22% Mass reduction - At no additional cost

    Light Weight Control Arm- Same mass as aluminum baseline- At 66% of the cost

    Steel Industry Investment in Automotive Lightweighting

    www.worldautosteel.org 8

    Body Structure Weight vs. Gross Vehicle Weight

    (a2mac1 database 2001-2008 production vehicles)

    450 Kg

    400

    350

    300

    200

    150

    250

    1000 Kg

    Body Structure: W/O Closures + IP Beam + Engine Cradle

    1500 2000 2500 3000Gross Vehicle Weight

    2001-2003 Steel BIW2004-2008 Steel BIW2004-2008 Top 10 Steel BIW

    Impact of AHSS Solutions

    -21%

  • www.worldautosteel.org 9

    Body Structure Weight vs. Gross Vehicle Weight

    (a2mac1 database 2001-2008 production vehicles)

    450 Kg

    400

    350

    300

    200

    150

    250

    1000 Kg

    Body Structure: W/O Closures + IP Beam + Engine Cradle

    1500 2000 2500 3000Gross Vehicle Weight

    2001-2003 Steel BIW2004-2008 Top 10 Steel BIWAluminium

    -28% -9%

    Impact of AHSS Solutions

    www.worldautosteel.org 10

    Source: Ducker Worldwide

    Impact of AHSS Solutions

    050

    100150200250300350400450

    2000 2005 2007 2009 2020

    AHSS (other)TRIP, CP,RAMartensiteBoronDP

    AHSS - Fastest Growing Automotive Material

    Pou

    nds

    per

    Veh

    icle

    www.worldautosteel.org 11

    Body Structure Weight vs. Gross Vehicle Weight

    (a2mac1 database 2001-2008 production vehicles)

    450 Kg

    400

    350

    300

    200

    150

    250

    1000 Kg

    Body Structure: W/O Closures + IP Beam + Engine Cradle

    1500 2000 2500 3000Gross Vehicle Weight

    2001-2003 Steel BIW2004-2008 Top 10 Steel BIWAluminium

    Impact of AHSS Solutions

    www.worldautosteel.org 12

    ULSABUltraLight Steel Auto Body

    ULSASUltraLightSteel Auto Suspensions

    ULSAB -AVCAdvanced VehicleConcepts

    www.worldautosteel.org

    ULSACUltraLight Steel Auto Closures

    Steel Industry Investment in Automotive Lightweighting

  • www.worldautosteel.org 13

    Why Future Steel Vehicle? The New Drivers

    Source: International Council on Clean Transportation

    USA

    JapanEurope

    Australia

    China

    100

    60

    80

    120

    160

    140

    180

    200

    220

    260

    240

    280

    Gra

    ms

    CO

    2 /K

    m (E

    quiv

    alen

    t)

    2003 2006 2009 2012 2015 2018 2021 2024 2027 2030Source: International Council on Clean Transportation

    USA

    JapanEurope

    Australia

    China

    100

    60

    80

    120

    160

    140

    180

    200

    220

    260

    240

    280

    Gra

    ms

    CO

    2 /K

    m (E

    quiv

    alen

    t)

    2003 2006 2009 2012 2015 2018 2021 2024 2027 2030

    Automotive CO2 Emissions Regulation.

    www.worldautosteel.org 14

    Honda Clarity FCX

    Mercedes F cell Mercedes E cell Plus

    Early Introductions of Dedicated PlatformAdvanced Powertrain Vehicles

    Why Future Steel Vehicle? The New Drivers

    www.worldautosteel.org 15

    Body Structure Weight vs. Gross Vehicle Weight

    (a2mac1 database 2001-2008 production vehicles)

    450 Kg

    400

    350

    300

    200

    150

    250

    1000 Kg

    Body Structure: W/O Closures + IP Beam + Engine Cradle

    1500 2000 2500 3000Gross Vehicle Weight

    2001-2003 Steel BIW2004-2008 Top 10 Steel BIWAluminiumSLC (Super Light Car)

    SLC states 35% mass reduction ( = 7.80 / kg)

    1.

    SLC is 20% less than avg. of best 10 steel ( = 14.20 / kg)

    2.

    Why Future Steel Vehicle? The New Drivers

    www.worldautosteel.org 16www.worldautosteel.org

    Future Steel vehicle willaddress:

    Future emissions regulations

    Advanced powertrains vehicles

    Competitive material solutions

    for 2015 to 2020

    Why Future Steel Vehicle? The New Drivers

  • www.worldautosteel.org 17

    What is New in Steel?FSVs Steel Portfolio

    Expanded range of steel gradesdenotes steel included in ULSAB-AVC

    Mild 140/270 DP 350/600

    BH 210/340

    BH 260/370 SF 570/640 DP 700/1000

    IF 260/410 MS 950/1200

    IF 300/420

    DP300/500

    DP 500/800

    HSLA 350/450 TRIP 450/800

    MS 1250/1500

    HSLA 490/600

    denotes steel grades added for FSV

    Mild 140/270 DP 350/600 TRIP 600/980

    BH 210/340 TRIP 350/600 TWIP 500/980

    BH 260/370 SF 570/640 DP 700/1000

    BH 280/400 HSLA 550/650 CP 800/1000

    IF 260/410 TRIP 400/700 MS 950/1200

    IF 300/420 SF 600/780 CP 1000/1200

    DP300/500 CP 500/800 DP 1150/1270

    FB 330/450 DP 500/800 MS 1150/1400

    HSLA 350/450 TRIP 450/800 CP 1050/1470

    HSLA 420/500 CP 600/900 HF 1050/1500

    FB 450/600 CP 750/900 MS 1250/1500

    HSLA 490/600

    www.worldautosteel.org 18

    Conventional StampingLaser Welded Blank

    Tailor Rolled BlankHigh Frequency Induction Welded Hydroformed TubesLaser Welded Hydroformed Tubes

    Tailor Rolled Hydroformed TubesHot Stamping (Direct & In-Direct)Laser Welded Blank Quench Steel

    Tailor rolled Blank Quench SteelRoll FormingLaser Welded Coil roll FormedTailor rolled Blank Roll Formed

    Roll Form with QuenchMulti Walled Hydroformed TubesMulti Walled Tubes

    Laser Welded Finalized TubesLaser Welded Tube Profiled Sections

    What is New in Steel?

    FSVs Manufacturing Options

    www.worldautosteel.org 19

    Donor Vehicle

    Donor Vehicle Rail

    A/SP LWB Concept

    TWTConcepts

    Mass Reduction

    22.4%

    32%

    45%

    FSV Pilot Program

    Topography Optimization

    FSV PilotProject

    Whats New in Design?

    Design Optimization

    www.worldautosteel.org 20www.worldautosteel.org

    Lightweighting technologies

    Expanded materials portfolio

    Expanded manufacturing technology portfolio.

    Aggressive design optimization technologies

    What is New in Steel?

  • www.worldautosteel.org 21

    Manufacturing Cost

    Future Steel Vehicle Performance Criteria

    $www.worldautosteel.org 22

    Source: Argon National Lab

    Mass Reduction

    Future Steel Vehicle Performance Criteria

    Source: International Council on Clean Transportation

    USA

    JapanEurope

    Australia

    China

    100

    60

    80

    120

    160

    140

    180

    200

    220

    260

    240

    280

    Gra

    ms

    CO

    2 /K

    m (E

    quiv

    alen

    t)

    2003 2006 2009 2012 2015 2018 2021 2024 2027 2030Source: International Council on Clean Transportation

    USA

    JapanEurope

    Australia

    China

    100

    60

    80

    120

    160

    140

    180

    200

    220

    260

    240

    280

    Gra

    ms

    CO

    2 /K

    m (E

    quiv

    alen

    t)

    2003 2006 2009 2012 2015 2018 2021 2024 2027 2030

    for fuel economy and emissions reduction

    www.worldautosteel.org 23

    Source: Argonne National Lab

    Vehicle Carbon Footprint

    Future Steel Vehicle Performance Criteria

    www.worldautosteel.org 24

    Effect of powertrain and fuel efficiency improvements

    24www.worldautosteel.org

    Source: UCSB Model

    0

    10,000

    5,000

    15,000

    20,000

    25,000

    30,000

    35,000

    9% 10% 12% 13% 20%

    24

    Future Steel Vehicle Performance Criteria

  • www.worldautosteel.org 25www.worldautosteel.org

    De