steel market development institute

w w w . s m d i s t e e l . o r g

Steel Market Development Institute

a business unit of AISIwww.smdisteel.org

A Steel Industry Perspective onAdvanced High-Strength Steels

Ronald KrupitzerVice President, Automotive Market

February 9, 2012AHSS Technology Workshop - Southfield MI


Outline

Automotive Steels Keeping Pace with Demand• Oil Crisis High Strength, HSLA Steels• PNGV ULSAB A/SP projects AHSS

New Challenges for Steel• Double Fuel Economy Mass reduction• New AHSS Grades Promises and Roadblocks


• Oil Crisis of 1973• Embargo by Arab Exporting Countries• High gasoline prices• Shortages with long lines at the pump• No lights on National Christmas Tree

Early HSS - HSLA


Oil Crisis

Early HSS - HSLA


• Steel High Strength Low Alloy Technology • (Alaska Arctic Line Pipe Project, 1970s)• Strength• Toughness• Weldability• Consistency• Low Cost

HSLA STEEL, X60 and X65

Early HSS - HSLA


55.9%

1.7%

15.0%

14.0%

3.0%

4.6%

2.2%

3.6%

Calendar Year 1975

Mild Steel

Medium and High Strength (HSLA) Steels

Other Steels

Iron

AluminumOther Metals

Other Materials

3,900 Pounds of Material Content

Plastics

Richard Schultz, Ducker Research, MST 2006

Early HSS - Materials Content

3.6%


Low StrengthSteels (<210MPa)

Ultra High Strength Steels (>550MPa)High Strength Steels

Elo

ngat

ion

(%)

Yield Strength (MPa)

0

10

20

30

40

50

60

70

0 400 600 1000200 800 1200

IF

MildIF

HSLA

BHCMn

IS

Conventional HSS

Growth of HSLASteels 1970-2000

Early HSS - HSLA

20 to 30 years of development


Early HSS - HSLA Metallurgy

Microally Additions of Columbium, Vanadium, Titanium

Fine Ferrite Grain Size

Precipitation Hardening

Low Sulfur and Inclusion Shape

Control


Early Issues - High Strength Steels

•Materials Uniformity (A/SP Project 1987-1995)•Tooling Costs, Tribology, etc. (A/SP 1987 -2012)•Stamping (A/SP 1989 - 2012)•Welding (A/SP 1989 – 2012)•HSS Design Manual (A/SP 1994-1996)

STAMPINGSTAMPING

TOOLINGTOOLING

WELDINGWELDING


•Partnership New Generation of Vehicles (PNGV)– 1993 Goal Fuel Economy of 80 MPG– USCAR and Federal Government– Lightweight Materials, but no Steel

•ULSAB Projects – Global Steel Initiative– Why ULSAB (1994-2002)– What it accomplished

ULSAB – Then AHSS Development


2002 ULSAB-AVC Mass Reduction

Source: WorldAutoSteel

ULSAB-AVC (2002)UltraLight Steel Auto Body -Advanced Vehicle Concept

- 25% (*) mass reduction - Improved crash performance- At no additional cost

ULSAS (2001)UltraLight Steel Auto Suspensions

- 25% - 34% (*) mass reduction - At no additional cost

ULSAC (2001)UltraLight Steel Auto Closures

- 25% - 30% (*) mass reduction - At no additional cost

* Mass Reductions versus PNGV Mild Steel Benchmark Vehicle

A Series of Global Vehicle Engineering Studies


2002-2009 A/SP Projects

Domestic (Auto/Steel Partnership) DOE-Funded EngineeringProjects 22% to 32% Weight Reduction, 2002-2009

FreedomCAR Goals50% mass reduction

same cost

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 Closures- 22% (*) mass reduction - At no additional cost

Lightweight Rear Chassis - 24% (*) mass reduction - At no additional cost

* Mass Reductions versus actual OEM donor vehicles


$022%Lightweight Closures7

-33%Equivalent mass to aluminum

Lower Control Arm8

$024%Lightweight Rear Chassis6

$032%Lightweight Front End Structures5

$030%Future Generation Passenger Compartment

4

$025%ULSAB-AVC3

$025-30%ULSAC2

$025-34%ULSAS1

CostMass ReductionProjectNo.

Cost of Steel-based Mass Reduction


ULSAB-AVC => First Generation AHSSE

long

atio

n (%

)

Tensile Strength (MPa)

0

10

20

30

40

50

60

70

0 600 1200300 900 1600

DP, CP

TRIP

MART

HSLA

IF

MildIF-HS

BHCMn

ISO

-

BH

First Generation AHSS (Dual Phase, TRIP, etc.)

2002-2012


Physical Metallurgy of AHSS

Actual MicrostructureSchematic Illustration

Dual Phase

Actual Microstructure

Martensite

TRIP

Actual Microstructure Schematic Illustration


AHSS Processing: Hot Dip Line


AHSS Processing: CA Line


The Hot Stamping Process

Punchingof Blanks


2007

43.1%

15.7%8.4%

7.0% 1.9%

0.2%

3.7%

8.1%

11.9%

Mild Steel

Other Steels

IronAluminum

Other Metals

Other Materials

Mag.

Plastics

Medium and High Strength Steels

Average North American 2007 Vehicle

Source: Ducker Worldwide

57%STEEL

4050 lbs.

Light Vehicle Materials Content


North American Net Material Content Per Light Vehicle in Pounds

757065Other Ferrous (PMP& SS)***

3,7553,5034,058Total Pounds/Curb Weight

540550581Glass, Rubber, Textiles etc

320213180Plastics and Composites

148130125Cu, Zn, Mg & other Metals

654214Other Aluminum

25917070Cast Aluminum

258333609Cast Iron

191*35-Advanced & Ultra HS Steels

357258146Bake Hard and HS Steels

1,5421,7022,268Mild Steel

200919951975Material

*Totals for 2009, 2015 and 2020 contains 40 lbs., 66 lbs. and 90 lbs. of AHSS long products **Excludes the impact of batteries for high volume electric and hybrid vehicles*** Powdered Metal Parts and Stainless Steel

Materials Trends

59%59%STEELSTEEL

59%59%STEELSTEEL

58%58%STEELSTEEL


Goal 1: Total Steel Content >57%

Total of 3,863 pounds, 58% steel


050

100150200250300350400450

2000 2005 2007 2009 2020

AHSS (other)TRIP, CP,RAMartensiteBoronDP

AHSS Growth in NA Vehicles

Source: Ducker Worldwide 2009

AHSS - Fastest Growing Automotive Material

Pou

nds

per V

ehic

le

Projected Market Penetration by 2020


BMW Implementation of AHSS

3´SeriesSedan5´Series

7´Series

1´Series

3´Series Sedan

7´Series 5´Series

5´SeriesSports Wagon



3´Series Sports W. 3´Series Coupé

3´SeriesCompact

Z4´Coupé

6´Series Coupé

3´SeriesCoupé

Z4

3´SeriesConvertible

6´Series Convertible

150

200

250

300

350

400

500

1994 1996 1998 2000 2002 2004 2006 2008 2010

Start of Production

Ave

rage

min

. Yie

ld S

treng

th (M

Pa)

Previous X5

Current X5X6

New 7 series

Doubling the strength of Body structural materials

over the last decade.

The Body in White of the New BMW 5 Series Gran Turismo,Duane Copeland and Markus Pfesdorf, BMW, GDIS 2010, Livonia MI

Implementation of AHSS


Mass and Performance Trends

Figure 19. Vehicle Weight and Performance since 1975 (Heavenrich 2006).


Increasing Crash Requirements

1990 1995 2000 2005 2010

1991FMVSS 208

30MPH Front

2003USNCAP35MPH Front

2012FMVSS 2163.0 X GVW

1994FMVSS 2161.5X GVW

2000SINCAP38.5MPH

Side

1995IIHS

40MPH 40%

1990FMVSS 214

Side

1997FMVSS 201Side Pole

2006IHSS Side

Higher, Heavier Barrier

2006FMVSS30155MPH 70%

2003FMVSS 30150MPH 50%

2009IIHS

4.0 X GVW


IIHS Side Impact Test


New CAFE Standards

Fuel Economy Regulations

20122012--2016 and 20172016 and 2017--20252025

MASS REDUCTIONMASS REDUCTION


Mass Reduction and Fuel Consumption

Determination of Weight Elasticity of Fuel Economy for Conventional ICE .Vehicles, Hybrid Vehicles and Fuel Cell Vehicles, fka Report 55510, June 2007

Source: WorldAutoSteel

2 to 5 %

5 to 8 %


Growing Threat from Competing Materials

Expect Ford’s next-generation F-Series full-size pickup to

feature aluminum body panels.

WardsAuto, Jan. 3, 2012


Pittsburgh Post Gazette, October 9, 2011

Growing Threat from Competing Materials


Representing 70% marketshare worldwide:

• Small cars(up to 4,000mm, A/B class)

• Mid-Class cars(up to 4,900mm, C/D class)

FutureSteelVehicle


More AHSS Grades = More Mass Reduction

FutureSteelVehicle’s Steel Portfolio

Expanded range of steel gradesdenotes steel included in ULSAB-AVC

Mild 140/270 DP 350/600BH 210/340BH 260/370 SF 570/640 DP 700/1000

IF 260/410 MS 950/1200IF 300/420DP300/500

DP 500/800HSLA 350/450 TRIP 450/800

MS 1250/1500HSLA 490/600

denotes steel grades added for FSV

Mild 140/270 DP 350/600 TRIP 600/980BH 210/340 TRIP 350/600 TWIP 500/980BH 260/370 SF 570/640 DP 700/1000BH 280/400 HSLA 550/650 CP 800/1000IF 260/410 TRIP 400/700 MS 950/1200IF 300/420 SF 600/780 CP 1000/1200DP300/500 CP 500/800 DP 1150/1270FB 330/450 DP 500/800 MS 1150/1400HSLA 350/450 TRIP 450/800 CP 1050/1470HSLA 420/500 CP 600/900 HF 1050/1500FB 450/600 CP 750/900 MS 1250/1500HSLA 490/600


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

T3

Mass Reduction Through Load Path and 3G Optimization with AHSS


Stamping AHSS

Roll-forming AHSS

Hydroforming AHSS

Extrusion Aluminum

Move together for flat mating condition

Independent Control Points

Rocker otr

Rocker reinf

Floor side inr

Hold seal flange

Design Space (common)

Section control points – constraining method determines the manufacturing solution

Mass Reduction Through Sub-System Optimization


Body Structure Mass(Actual vs. Regression Analysis Prediction)

100

150

200

250

300

350

400

200 250 300 350 400Body Structure Mass (Regression Analysis Prediction)

Bod

y St

ruct

ure

Mas

s (A

ctua

l)

a2mac1 (database)ULSAB-AVC Ref.ULSAB-AVCFSVAluminum

35

FSV Compared to UltraLight – Mass

11%

Source – A/SP Benchmarking Project

1998ULSAB_AVCRef. Vehicle

Audi A2

Jaguar XK

Audi TT

ULSAB-AVC

Steel Mass Similar to Aluminum

35%


AAC Project Addressing Threats

WHEELS

Multi-LinkTwist Beam

Struts & Links Lotus Unique

Upper Wishbone

Lower Wishbone

Multi-LinkTwist Beam

Struts & Links Lotus Unique

Upper Wishbone

Lower Wishbone

SUSPENSIONS

CLOSURES

FUEL TANKS

Lower Control Arm, 2010 – 2011Twist Beam - 2012

Doors, 2011 – 2012 Wheels, 2011 – 2012

Fuel Tanks, 2010 – 2011


New 3rd Generation AHSS Grades offer more mass reduction with AHSS, because more parts can be made at high strength

For 2017-2025, new formable AHSS grades will

enable more steelmass reduction

3rd Generation of AHSS

Elo

ngat

ion

(%)

Tensile Strength (MPa)

0

10

20

30

40

50

60

70

0 600 1200300 900 1600

DP, CP

TRIP

MART

HSLA

IF

MildIF-HS

BHCMn

ISO

-

BH

TWIPAUST. SS

L-IP

Future Opportunity

Third Generation AHSS


LCA Research at UC DavisLCA of Lotus Study

(HD vs LD BIW)

0

10,000

20,000

30,000

40,000

50,000

60,000

HD BIW LD BIW

Kg

CO

2e

7%

Al, Magnesium, Al, Magnesium, C Fiber StructureC Fiber Structure

AHSS AHSS StructureStructure

Materials Matter

Bill of Materials Approach for OEMs

ProductionProduction

UseUse

RecyclingRecycling


• Steel products have kept pace with OEM demands for decades.

• New aggressive fuel economy standard are putting a premium on mass reduction, right or wrong.

• Optimized (3G - gage, geometry, grade) steel structures approach the mass of aluminum structures in many cases.

• 10% mass reduction results in 2 - 3.5% reduction in fuel consumption for ICE vehicles and 5.5 - 8.2% if powertrains are resized.

• 3rd Generation AHSS grades are being researched and will add more mass reduction capability for steel parts which today cannot be easily formed.

• WorldAutoSteel’s FutureSteelVehicle project is an engineering study showing the growing potential of steel to fulfill future vehicle demands.

• LCA gives a decided advantage to steel in terms of enabling lower total emissions in future high-fuel-economy vehicles.

Steel Conclusions

steel market development institute

Documents