future steel vehicle advanced powertrains and the influence on material...
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w w w . a u t o s t e e l . o r g
Harry Singh (EDAG FSV Program Manager)
Future Steel Vehicle and the influence on Material Selection
Great Designs in Steel: May 13
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Harry Singh
Future Steel Vehicle – Advanced Powertrains
and the influence on Material Selection
Great Designs in Steel: May 13th 2009
1. Introduction:
EDAG – brief overviewWorldAutoSteel, Sponsoring Companies
2. WorldAutoSteel – Future Steel Vehicle (FSV)
• Advanced Power Train Systems HEV, PHEV, BEV, FCEV
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• Advanced Power Train Systems HEV, PHEV, BEV, FCEV
• Well to Wheels efficiencies
• FSV Materials Portfolio
WorldAutoSteel, Sponsoring Companies
Future Steel Vehicle (FSV)
Advanced Power Train Systems HEV, PHEV, BEV, FCEV
Overview
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Advanced Power Train Systems HEV, PHEV, BEV, FCEV
Well to Wheels efficiencies
FSV Materials Portfolio
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Product Development Engineering Services
� Styling
� Design & Engineering
� Computer Simulation
In USA since 1994, 350 employees
EDAG - Overview
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Product Development Engineering Services
In USA since 1994, 350 employees
WorldAutoSteel, the automotive group of the World Steel Association, continually
explores steel innovation that demonstrates the value of steel to the automotive
industry.
WorldAutoSteel member companies from around the world pool global resources to
deliver vital research that is central to effective steel automobile applications.
ArcelorMittal - Luxembourg
Baoshan Iron & Steel Co. Ltd. - China
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Baoshan Iron & Steel Co. Ltd. - China
China Steel Corporation - Taiwan, China
Hyundai-Steel Company - South Korea
JFE Steel Corporation - Japan
Kobe Steel, Ltd. - Japan
Nippon Steel Corporation - Japan
Nucor Corporation - USA
WorldAutoSteel, the automotive group of the World Steel Association, continually
explores steel innovation that demonstrates the value of steel to the automotive
WorldAutoSteel member companies from around the world pool global resources to
deliver vital research that is central to effective steel automobile applications.
WorldAutoSteel Members
POSCO - South Korea
Severstal - Russia/USA
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Severstal - Russia/USA
Sumitomo Metal Industries, Ltd. - Japan
Tata Steel & Corus - India, UK, Netherlands
ThyssenKrupp Stahl AG - Germany
United States Steel Corporation - USA
Usinas Siderurgicas de Minas Gerais S.A. -
Brazil
Voestalpine Stahl GmbH - Austria
WorldAutoSteel continues to lead the materials revolution through
projects like the Ultra Light Steel Family of Research:
• ULSAB, ULSAC, ULSAS (BIW, Closures & Suspensions)
• ULSAB-AVC (Advanced Vehicle Concepts)
WorldAutoSteel’s newest program Future Steel Vehicle (FSV)
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WorldAutoSteel’s newest program Future Steel Vehicle (FSV)
Part 1 – Engineering Study (2008 –
Part 2 – Concept Design (July 2009 -
Part 3 – Demonstration Hardware (2010
WorldAutoSteel continues to lead the materials revolution through
projects like the Ultra Light Steel Family of Research:
ULSAB, ULSAC, ULSAS (BIW, Closures & Suspensions)
AVC (Advanced Vehicle Concepts)
Future Steel Vehicle
WorldAutoSteel’s newest program Future Steel Vehicle (FSV)
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WorldAutoSteel’s newest program Future Steel Vehicle (FSV)
– July 2009)
- 2010)
Demonstration Hardware (2010 - 2011)
FSV Objective:
Strengthen Steel’s Position as the Automotive Structural Material of Choice for the
Future Vehicles (2020) & identification of new applications for steel.
FSV Justification:
Global growth of vehicle fleet from 820,000,000 vehicles in
2008 to 1 billion by 2020.
Transportation at present is 96% dependence on petroleum.
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Transportation at present is 96% dependence on petroleum.
Daily worldwide petroleum usage 85,000,000 barrels
Vehicle emissions standards: EU 130 CO2 g/km 2009 & 95
g/km 2020, Japan 145 g/km 2009, USA CAFE 35mpg 2015.
Increasing vehicle efficiencies to reduce petroleum
consumption & to reduce Green House Gas emissions:
are the key drivers for the implementation of Advanced
Powertrains with increased focus on Vehicle Mass Reduction
Strengthen Steel’s Position as the Automotive Structural Material of Choice for the
Future Vehicles (2020) & identification of new applications for steel.
Future Steel Vehicle
Global growth of vehicle fleet from 820,000,000 vehicles in
Transportation at present is 96% dependence on petroleum. COCOCOCO2222
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Transportation at present is 96% dependence on petroleum.
worldwide petroleum usage 85,000,000 barrels
EU 130 CO2 g/km 2009 & 95
g/km 2020, Japan 145 g/km 2009, USA CAFE 35mpg 2015.
Increasing vehicle efficiencies to reduce petroleum
consumption & to reduce Green House Gas emissions:
are the key drivers for the implementation of Advanced
Vehicle Mass Reduction.
COCOCOCO2222
FSV: Phase 1
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FSV: Phase 1 – Engineering Study
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The assessment of the announcements from automobile manufacturers show progress on various technologies which include;
1. Conventional internal combustion engine (ICE) based smaller more efficient gasoline/diesel vehicles
2. Higher efficiency Hybrid Electric Vehicle (HEV)
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3. Plug-in hybrids (PHEV) with limited range of miles driven in Electric Mode. This option offer significant reduction in fossil based petroleum usage, especially when the daily distances driven are close to the vehicle’s electric range. The additional distance being driven using petroleum or Bio
4. Battery Electric Vehicles (BEV) with driving range of approximately 200 km
5. Fuel Cell Electric Vehicles (FCEV) using hydrogen gas as a fuel source
The assessment of the announcements from automobile manufacturers show progress on various technologies which include;
Conventional internal combustion engine (ICE) based smaller more
Higher efficiency Hybrid Electric Vehicle (HEV)
FSV - OEM Direction/Trends
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in hybrids (PHEV) with limited range of miles driven in Electric Mode. This option offer significant reduction in fossil based petroleum usage, especially when the daily distances driven are close to the vehicle’s electric
The additional distance being driven using petroleum or Bio-fuels
Battery Electric Vehicles (BEV) with driving range of approximately 200 km
5. Fuel Cell Electric Vehicles (FCEV) using hydrogen gas as a fuel source
A broad range of alternate propulsion vehicles have been announced by automakers
around the world. The following table shows the number of vehicles announced by
OEMs (Concept and Production)
Electric only Plug-in Hybrid
BEV 18
PHEV -
OEM Announcements
Futu
re S
teel
Vehic
les
Type
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PHEV -
FCEV -Futu
re S
teel
Vehic
les
Mitsubishi (2009) Subaru (C) Mercedes (2011) Th!nk (2009)BMW (2015) Tesla (2009) BMW (2009) Nissan (2010) NICE (2009) Dodge (2010)Toyota (2012) REVA (C)BYD(2011) TATA (2011)Ford (2011) Magna (C)
FSV - OEM Announcements
A broad range of alternate propulsion vehicles have been announced by automakers
around the world. The following table shows the number of vehicles announced by
Plug-in Hybrid Fuel Cell
- -
9 -
OEM Announcements
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9 -
- 4
Honda (2009)GM (C)Hyundai (C)Mercedes (C)
GM (2011) GM (2010)Fisker (2010)Chrysler (2012)Toyota (2010) Mercedes (2012)BYD (2009)Volvo (C)
(XXXX) – Proposed year of production
(c) – Concept Vehicle
F
PHEV (Plug-in Hybrid Electric Vehicle) Toyota – Prius PHEV
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BEV (Battery Electric Vehicle) Mitsubishi - I MiEV
Future Advanced Powertrains
EREV (Extended Range Electric Vehicle) GM - VOLT
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GM - VOLT
FCEV (Fuel Cell Electric Vehicle) Fuel Compressed Hydrogen Gas Honda - Clarity
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Daimler Smart for-two 2695 mm
TATA nano 3100mm – 4 Occupants
Small Cars can be affordable, safe & fun, and HEV & BEV’s
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TATA nano 3100mm – 4 Occupants
Toyota IQ 2985mm – 3+ Occupants
70
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70
FSV – Fuel Cell Technology Assessment
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kWh/kg
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FSV – BEV Battery Technology Assessment
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Petroleum to Li
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Approx 110 Wh (90 Wh for small car) of energy required per km of driving
For small car 5 kWh battery driving range 32 km (year 2015 cost estimate $2,346)
For mid-size car 12 kWh battery driving range 64 km (year 2015 cost estimate $5,400)
Petroleum to Li-ion Batteries?
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Approx 110 Wh (90 Wh for small car) of energy required per km of driving
For small car 5 kWh battery driving range 32 km (year 2015 cost estimate $2,346)
size car 12 kWh battery driving range 64 km (year 2015 cost estimate $5,400)
USA
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PHEV40 – 70% daily miles driven in Electric mode
Miles
Europe
PHEV20 – 50% daily miles driven in Electric mode
Vehicle Daily Distances Traveled
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km
FSV 1
PHEV20
Electric Range – 32kmTotal Range – 500km
Max Speed -150km/h
0-100 km/h 11-13 s
Worldwide over 70% market share between two vehicle sizes: Small car
(up to 4,000mm, A/B class) and Mid
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FSV 2
PHEV40
Electric Range – 64kmTotal Range – 500km
Max Speed -161km/h
0-100 km/h 10-12 s
Range based on UDDS cycle
FSV: Vehicle Size & Power Trains
20
32km500km
150km/h
13 s
BEV
Total Range – 250km
Max Speed -150km/h
0-100 km/h 11-13 s
Worldwide over 70% market share between two vehicle sizes: Small car
(up to 4,000mm, A/B class) and Mid-Class car (up to 4,900mm, C/D class)
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0-100 km/h 11-13 s
40
64km500km
161km/h
12 s
FCEVTotal Range– 500km
Max Speed -161km/h
0-100 km/h 10-12 s
Range based on UDDS cycle
FS
Occupants:
Front Row Seating – 2
Rear Row Seating – 2+
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Vehicle Class Average Front Leg Room
A 1055
B 1065
C 1070
D 1075
1065 mm
FSV1: Occupants, Front & Rear Leg Room and Luggage Targets
825 mm
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Average Front Leg Average Rear Leg Room
760
850
877
961
Luggage Liters
170
340
370
450
250 Liters
FS
Occupants:
Front Row Seating – 2
Rear Row Seating – 3
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Vehicle Class Average Front Leg Room
A 1055
B 1065
C 1070
D 1075
1065 mm
FSV2: Occupants, Front & Rear Leg Room and Luggage Targets
920 mm
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Average Front Leg Average Rear Leg Room
760
850
877
961
Luggage Liters
170
340
370
450
370 Liters
FSV:
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V: Advanced Powertrains Concept Layouts
FSV: BEV Battery Electric Vehicle
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Vehicle
FSV: FCEV Fuel Cell Electric Vehicle
FSV: PHEV40
Plug-in Hybrid Electric Vehicle
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At present vehicle use (Pump to Wheel) Fuel consumption:
km/l or CO2 g/km or mpg
FSV: Total Life Cycle Assessment (LCA)
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1. Green House Gas CO2: g/km
2. Energy Efficiency: wh/km
3. Cost of Ownership: $/km
LCA: For Vehicle life of 200,000 km
FSV
Well to Pump
Internal Combustion Engine100
80
84
Gasoline Production
Bio Fuel:
Ethanol
Diesel
Diesel Production
38
31
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Engine100 units of energy
38Electricity Generation US-Mix
H2 - NG Reformation 62
Greet 1.8b Argonne National Lab
91.5Renewable
Electric Motor Drive
FCEV
SV: Efficiency of Fuels and Energy Sources
16
21
8
8
Diesel 25-40 % efficient
Bio-Diesel 25-40 % efficient
Gasoline 20-35 % efficient
Ethanol 22-37 % efficient
Combustion
Pump to Wheel Well to Wheel
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8Bio-Diesel 25-40 % efficient
20
7031
9
21
27 24 10
35 33
57 23
Motor DriveBEV
FCEV
FSV1
3
4
5
6
7
Gasoline
PHEV20 - CS
PHEV20 - 65km
PHEV20 - 150km
PHEV20 - 500km
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CD – charge depleting – energy from battery CS – charge sustaining – energy from petroleum, similar to HEV
0.0 20.0 40.0 60.0 80.0
1
2
CO2 Emissions in g/km
PHEV20 32km CD
BEV
0
0
FSV1 - Pump to Wheel CO2 Emission g/km
Pump to Wheel
100 kg Vehicle Mass Reduction
130 g/km 2012 EU
34 mpg, 14.4 km/l, 7.0 l/100km
95 g/km 2020 EU
110
Toyota Prius 2010
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energy from battery energy from petroleum, similar to HEV
80.0 100.0 120.0 140.0 160.0 180.0 200.0
CO2 Emissions in g/km
140 g/km 2009 JAMA (voluntary)
USA - Electricity Production
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Results also available for Europe, India, China, Japan, 100% coal, 100% Renewable
FSV: Electricity Production
Electricity Production
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[Source: Greet 1.8b US-Mix]
Results also available for Europe, India, China, Japan, 100% coal, 100% Renewable
FSV1
2
3
4
5
6
7Gasoline
PHEV20 - CS
PHEV - 32km CD
PHEV20 - 65km
PHEV20 - 150km
PHEV20 - 500km
E50J57
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-10.0 10.0 30.0 50.0 70.0 90.0
1
2
CO2 Emissions in g/km
E50 Electricity Mix Europe
PHEV20 - 32km CD
BEV
E50J57
CD – charge depleting – energy from battery CS – charge sustaining – energy from petroleum, similar to HEV
0
FSV1 - Well to Wheel CO2 Emissions g/km
Well to Pump (US Mix Electricity)
Pump to Wheel
100 kg Vehicle Mass Reduction
114
138
Toyota Prius 2010
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110.0 130.0 150.0 170.0 190.0 210.0 230.0 250.0
CO2 Emissions in g/km
J57 Electricity Mix Japan
114
Electricity 100% Coal110
energy from battery energy from petroleum, similar to HEV
FSV2
3
4
5
6
7
8Gasoline
PHEV40 - CS
PHEV40 64km CD
PHEV40-100km
PHEV40-250km
PHEV40-500km
0
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0.0 20.0 40.0 60.0 80.0
1
2
CO2 Emissions in g/km
CD – charge depleting – energy from battery CS – charge sustaining – energy from petroleum, similar to HEV H2 NG – Hydrogen from Natural Gas H
FCEV H2 - NG
FCEV H2 - Elec
0
0
FSV2 - Pump to Wheel CO2 Emission g/km
Pump to Wheel
100 kg Vehicle Mass Reduction
130 g/km 2012 EU
29 mpg, 12.5 km/l, 8.0 l/100km
95 g/km 2020 EU
134
Ford Fusion HEV 2010
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80.0 100.0 120.0 140.0 160.0 180.0 200.0
CO2 Emissions in g/km
energy from battery energy from petroleum, similar to HEV
Hydrogen from Natural Gas H2 Elec – Hydrogen from H2O Electrolysis
140 g/km 2009 JAMA (voluntary)
FSV2
4
5
6
7
8Gasoline
PHEV40 - CS
PHEV40-100km
PHEV40-250km
PHEV40-500km
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-10.0 10.0 30.0 50.0 70.0 90.0 110.0
1
2
3
CO2 Emissions in g/km
FCEV H2 - Elec
FCEV H2 - NG
PHEV40 64km CD
CD – charge depleting – energy from battery CS – charge sustaining – energy from petroleum, similar to HEV H2 NG – Hydrogen from Natural Gas H2 Elec
FSV2 - Well to Wheel CO2 Emission g/km
Well to Pump (US Mix Electricity)
Pump to Wheel
100 kg Vehicle Mass Reduction
168
Ford Fusion HEV 2010
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110.0 130.0 150.0 170.0 190.0 210.0 230.0 250.0
CO2 Emissions in g/km
energy from battery energy from petroleum, similar to HEV
Hydrogen from Natural Gas H2 Elec – Hydrogen from H2O Electrolysis
FS
●●●● Gasoline AT
●●●● Gasoline CVT
●●●● Gasoline MT
●●●● Hybrid
▲▲▲▲ Diesel
▲▲▲▲ LPG
CO
2
(g/k
m)
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Vehicle Mass (kg)PHEV, CD – Battery Charge Depleting
BEV – Electric Vehicle
FCEV – Fuel Cell Vehicle
PHEV20, CS – Battery
Charge Sustaining
FSV: Pump to Wheel CO2 g/km comparison
ICE
Hybrid
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Vehicle Mass (kg) FSV – PHEV20 & PHEV40
70% Miles Driven in EV mode – Energy from Electric Grid
30% Miles Driven in HEV mode – Energy from Petroleum
PHEV40, CS – Battery
Charge Sustaining
Part 1 – Engineering Study (2008 – July 2009)
Part 2 – Concept Body Structure Design (July 2009
Part 3 – Demonstration Hardware (2010
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July 2009)
Concept Body Structure Design (July 2009 - 2010)
Demonstration Hardware (2010 - 2011)
Future Steel Vehicle
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FSV: Phase 2
• Investigate the vehicles mass reduction potential with the use of Advanced High Strength Steel (AHSS), advanced manufacturing technologies and use of computer aided structural optimization.
• Understand the loads imposed by advanced powertrains on the vehicle structure and hence identify requirements for new grades of steel for optimized low mass vehicle structural applications and designs.
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designs.
FSV: Phase 2 – Concept Design
Investigate the vehicles mass reduction potential with the use of Advanced High Strength Steel (AHSS), advanced manufacturing technologies and use of computer aided structural optimization.
Understand the loads imposed by advanced powertrains on the vehicle structure and hence identify requirements for new grades of steel for optimized low mass vehicle structural applications and
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BIW Wt. vs. GVW
300
350
400
450
BIW
(K
g)
'01 - '03 Steel BIWULSAB-AVC
Aluminum BIW'04 - '08 Steel BIW
Top 10 Steel BIWEU Super Light CarLinear ('01 - '03 Steel BIW)
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150
200
250
300
1000 1500
GVW (Kg)
BIW
(K
g)
BIW Wt. vs. GVW
FSV – Body Structure Mass Targets
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2000 2500 3000
GVW (Kg)
Future Steel Vehicle
• Battery Electric
• Plug-in HEV
• Fuel Cell
Low StrengthSteels (<210MPa)
Ultra High Strength Steels (>550MPa)
High Strength Steels
Elo
ng
ati
on
(%
)
30
40
50
60
70
Mild
BHBH
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Elo
ng
ati
on
(%
)
Tensile Strength (MPa)
0
10
20
0 600 1200300 900
MART
ULSAB Program: Achieved 25% reduction in BIW Mass
Ultra High Strength Steels (>550MPa)
Steel Grades for ULSAB (2000)
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1200 1600
MART
ULSAB Program: Achieved 25% reduction in BIW Mass
Low StrengthSteels (<210MPa)
Ultra High Strength Steels (>550MPa)
High Strength Steels
Elo
ng
ati
on
(%
)
30
40
50
60
70
Mild
BHBH
Steel Grades for ULSAB
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Elo
ng
ati
on
(%
)
Tensile Strength (MPa)
0
10
20
0 600 1200300 900
MART
ULSAB – ABC Program: Achieved 24% reduction in BIW Mass
Ultra High Strength Steels (>550MPa)
Steel Grades for ULSAB – AVC (2004)
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1200 1600
MART
Low StrengthSteels (<210MPa)
High Strength Steels
Elo
ng
ati
on
(%
)
30
40
50
60
70
Mild
Steel
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Elo
ng
ati
on
(%
)
Tensile Strength (MPa)
0
10
20
30
0 600300
BHBH
Ultra High Strength Steels (>550MPa)
el Grades Availability for FSV (2020)
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Tensile Strength (MPa)
1200900 1600
MART
FSVChoice of Steel
Grades
Steel
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el Grades Availability for FSV (2020)
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Manu
Manufacturing Techniques considered for the WorlAutoSteel ULSAB & ULSAB-AVC programs.
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nufacturing Processes ULSAB
Manufacturing Techniques considered for the WorlAutoSteel ULSAB &
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Manufacturing Techniques available (existing and emerging) that are being considered for the WorlAutoSteel FSV program.
M
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Manufacturing Techniques available (existing and emerging) that are being considered for the WorlAutoSteel FSV program.
Manufacturing Processes FSV
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WorldAutoSteel – Future Steel Vehicle (FSV)
• Advanced Power Train Systems PHEV
• Well to Wheels efficiencies
• FSV Materials portfolio
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Part 1 – Engineering Study (2008
Part 2 – Concept Body Structure Design (July 2009
Part 3 – Demonstration Hardware (2010
Future Steel Vehicle (FSV)
Advanced Power Train Systems PHEV20, PHEV40, BEV, FCEV
Well to Wheels efficiencies
Summary
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Engineering Study (2008 – July 2009)
Concept Body Structure Design (July 2009 - 2010)
Demonstration Hardware (2010 - 2011)