reinventing automotive steel - california air resources board · reinventing automotive steel...
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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
Today’s 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?FSV’s 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?
FSV’s 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
What’s 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
Design Performance Criteria
•Manufacturing cost
•Mass reduction
•Vehicle’s carbon foot print
Future Steel Vehicle Performance Criteria
www.worldautosteel.org 26
FSV 1
4-door hatchback
3700 mm
PHEV20
Electric Range: 32km
Total: 500km
Max Speed: 150km/h
0-100 km/h 11-13 s
BEV
Total Range: 250km
Max Speed: 150km/h
0-100 km/h 11-13 s
FSV 2
4-door sedan
4350 mm
PHEV40
Electric Range: 64km
Total: 500km
Max Speed: 161km/h
0-100 km/h 10-12 s
FCEV
Total Range: 500km
Max Speed: 161km/h
0-100 km/h 10-12 s
Vehicle Size & Powertrain Configurations
What is Future Steel Vehicle?
•Common front end•Common front wheel drive traction motor
Range based on UDDS cycle
www.worldautosteel.org 27
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-System3G Optimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
Future Steel Vehicle –Design Methodology
www.worldautosteel.org 28
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-System3G Optimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
Future Steel Vehicle –Design Methodology
T1
www.worldautosteel.org 29
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-System3G Optimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
Future Steel Vehicle –Design Methodology
T1
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T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-System3G Optimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
Future Steel Vehicle –Design Methodology
T1
www.worldautosteel.org 31
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-SystemTopographyOptimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
Future Steel Vehicle – Design Methodology
T1
T2
www.worldautosteel.org 32
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-SystemTopographyOptimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
T2
Future Steel Vehicle – Design Methodology
www.worldautosteel.org 33
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-System3G Optimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
T2
Future Steel Vehicle – Design Methodology
T3
www.worldautosteel.org 34
Future Steel Vehicle –Design Methodology
www.worldautosteel.org 35
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-System3G Optimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
Future Steel Vehicle – Design Methodology
T3
www.worldautosteel.org 36
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-System3G Optimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
Future Steel Vehicle – Design Methodology
T3T4
www.worldautosteel.org 37
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-System3G Optimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
T4
Future Steel Vehicle – Design Methodology
Detailed Steel Alternative Solutions for Critical Load Paths
www.worldautosteel.org 38
LWB
TRB
Blanks
ConventionalStamping
RollForming Hydroforming
HotStamping
Future Steel Vehicle –Design Methodology
www.worldautosteel.org 39
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-System3G Optimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
T4
Future Steel Vehicle – Design Methodology
Detailed Steel Alternative Solutions for Critical Load Paths
www.worldautosteel.org 40
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-SystemTopographyOptimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
T4
Future Steel Vehicle –Design MethodologySubsystem Optimization
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HF3GTechnologyAssessment
High Volume Manufacturing
Feasibility
Sub-System Mass (kg)
Manufacturing
Cost ($)
LCA CO2Savings
(kg)
Baseline B ST Stamping Conservative 10.26 19.99 0
ST Stamping Conservative 10.95 21.33 53
ST TRB Stamping TRB Mid-Term 10.52 24.18 16
ST LWB Stamping LWB Conservative 10.47 27.86 30
HST Hot Stamp Conservative 9.80 24.98 -37
HST TRB Hot Stamp TRB Mid-Term 9.66 27.68 -47
HST LWB Hot Stamp LWB Mid-Term 9.66 31.60 -37
RF Roll Form Conservative 7.98 14.18 -183
RF TRB Roll Form TR Coil Aggressive 7.95 16.47 -189
RF TWC Roll Form TW Coil Conservative 8.07 15.66 -177
HF HydroForm Conservative 7.05 22.80 -248
HF LWT Hydroform LWT Mid-Term 6.96 27.89 -245
HF MWT Hydroform MWT Aggressive 6.96 23.91 -255
Aluminum AL Extrusion Mid-Term 7.53 39.70 -204
HF3GManufacturing Interpretation
Stamping Solution( HEEDS Mass)
Hydroform(HEEDS Mass)
Roll Form(HEEDS Mass)
FSV – Rocker Cost, Mass & LCA CO2 eq Assessment
Subsystem Optimization - Rocker
www.worldautosteel.org 42
$10
$15
$20
$25
$30
$35
$40
$45
Co
st ($
)
4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00
Mass (Kg)
IncreasingValue
Rocker Technology Options(Mass vs Cost Value)
Parallels of Constant Value ($9.39/kg)
FSV – Mass Paradigm Shift
Subsystem Optimization - Rocker
www.worldautosteel.org 43
$10
$15
$20
$25
$30
$35
$40
$45
Cos
t ($
)
Al
HF LWT
HF
RF
RF TWC
HF TRB
RF TRB
HS LWB
ST TRB
HS TRB
ST
ST LWBHS
4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00
Mass (Kg)
IncreasingValue
Rocker Technology Options(Mass vs Cost Value)
Parallels of Constant Value ($9.39/kg)
FSV – Rocker Cost & Mass Assessment
Subsystem Optimization - Rocker
www.worldautosteel.org 44
Rocker Technology Options(Mass vs Cost Value)
Parallels of Constant Value ($9.39/kg)LCA CO2 eq. Saved (Kg) vs. Cost ($)
$10
$15
$20
$25
$30
$35
$40
$45
Cos
t ($
)
Al
HF LWT
HS LWB
ST TRB
HS TRB
HF
RF
RF TWC
ST
ST LWBHSHF TRB
RF TRB
B ST
4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00
Mass (Kg)
IncreasingValue
-300 -250 -200 -150 -100 -50 0 50 100
LCA CO2 Saved (Kg)LCA CO2 eq. Saved (Kg)
FSV – Rocker Cost & LCA CO2 eq Assessment
www.worldautosteel.org 45
Shotgun Technology Options(Mass vs Cost Value)
Parallels of Constant Value ($9.39/kg)
$10
$20
$30
$40
$50
$60
4.00 4.50 5.00 5.50 6.00 6.50 7.00
Mass (Kg)
Co
st ($
)
ST TRBHST TRB
HST LWB
AL
ST
ST LWB
HST
50 75 100 125 150 175 200
LCA CO2 Saved (Kg)
LCA CO2 eq. Saved (Kg) vs. Cost ($)
-300 -250 -200 -150 -100 -50 0 50 100
LCA CO2 Saved (Kg)LCA CO2 eq. Saved (Kg)
FSV – Shotgun , Cost & LCA CO2 eq Assessment
Subsystem Optimization - Shotgun
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Rocker Technology Options(Mass vs Cost Value)
Parallels of Constant Value ($9.39/kg)
ST LWB
HST LWB
HF
HF LWT
HF TRT
AL
ST
ST TRBHST
HST TRB
RF
RF TRBRF TWC
B ST
$10
$15
$20
$25
$30
$35
$40
$45
6.00 7.00 8.00 9.00 10.00 11.00 12.00
Mass (Kg)
Cos
t ($)
increasingvalue
Rocker Technology Options(LCA CO2 reduction, Cost & Value)
Parallels of Constant Value ($100/tonne)
AL
ST TRB
ST LWB
HST
HST TRB
HST LWB
RF
HF LWT
HF TRT
RF TRB RF TWC
HFB ST
$10
$15
$20
$25
$30
$35
$40
$45
-400 -350 -300 -250 -200 -150 -100 -50 0 50
LCA CO2 Saved (Kg)
Cos
t ($)
increasingvalue
FSV – Rocker, Cost, Mass & LCA CO2e Assessment
www.worldautosteel.org 47
FSV – Shotgun, Mass & LCA CO2e Assessment
www.worldautosteel.org 48
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-SystemTopographyOptimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
T4
FSV – Structural Subsystem Technology Assessment
www.worldautosteel.org 49
T1
T6
T5T4
T3
T2 Linear-StaticTopology
Optimization
GaugeOptimization
Final DesignConfirmation
Phase1Technology Assessment
Packaging
Non-Linear Dynamic Topology Optimization
(LF3G)Sub-SystemTopographyOptimization
Detail Design
Styling & aerodynamic
DesignConfirmation
Phase 2Report
T4T5
FSV – Structural Subsystem Technology Assessment
Strong, Safe, Sustainable
Thank you for your attention