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THE ROLE OF STEEL IN FUTURE MOBILITY
The value of steel in the automotive industry and continued
development of new automotive steels
John Catterall
Vice President, Automotive Program
American Iron and Steel Institute
September 2, 2020
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Steel Industry Collaboration
Increases the use of steel by developing
innovative materials and applications by
working with automotive customers
Automotive Applications Council
Advances and
communicates steel’s
unique ability to meet
the automotive
industry’s needs and
challenges in a
sustainable and
environmentally
responsible wayPre-competitive Collaborative
Research & Development;
Leveraging joint contributions and
intellectual capital providing more
value and quicker results
https://www.worldautosteel.org/
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For Internal Use – Not for Public Sharing
While the ultimate future of mobility may remain unclear,
the fundamental need for movement of people and goods
will not significantly change…
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Automated, Connected, Electrified & Shared Mobility
– Steel Impact
“Automated, Connected, Electric, and Shared (ACES) vehicle
technologies are compelling automotive engineers
to reevaluate vehicle design, materials, and manufacturing
technologies.” – Center for Automotive Research
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There are many new
EV entrants…
• Tesla
• Lucid
• Nio
• Canoo
• Rivian
• and more…
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“Within the decade…
seven out of 10 new
pickup trucks produced
in North America will be
aluminum-bodied.”
- Ducker Worldwide 2014
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In FACT, since launch of Ford F-150, the last 7 pickups remained
steel
Ford F150 – Aluminum
SUCCESS THROUGH COLLABORATION –
“7 OUT OF 10 PICKUPS”
GM - Silverado / Sierra Toyota –Tacoma FCA - Wrangler /
Gladiator Ford – Ranger
FCA – RAM GM - Colorado / Canyon Nissan – Titan
2019 Production ~4MM full and mid-sized pickup trucks worth 3.0
- 3.5MM tons of sheet steel
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The steel industry has a long history of successfully
partnering
with global automakers to develop highly optimized, cost
effective
and mass efficient solutions:
• Ultra-lightweight Steel Auto Body
• Future Steel Vehicle
The results of the Future Steel Vehicle were rapidly and
widely
adopted by automakers as evident in 2015 model year
vehicles.
The Role of Steel in Future Mobility
FUTURE MOBILITY WILL BE NO EXCEPTION
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Steel Landscape & Continuous Innovation
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Innovation through Collaboration
Long History of Partnering with Global Automakers
FUTURE STEEL VEHICLE (FSV) – Electric Vehicle Architecture
1. State-of-the-future design
2. 35% mass reduction
3. 97% HSS/AHSS
4. ~50% UHSS
5. 5-star safety
6. Decreased life cycle emissions
7. No cost penalty
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FSV Steel Portfolio
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Conventional Stamping
Laser Welded Blank
Tailor Rolled Blank
Induction Welded Hydroformed Tubes
Laser Welded Hydroformed Tubes
Tailor Rolled Hydroformed Tubes
Hot Stamping (Direct & In-Direct)
Laser Welded Blank Quench Steel
Tailor Rolled Blank Quench Steel
Roll Forming
Laser Welded Coil Rollformed
Tailor Rolled Blank Rollformed
Rollform with Quench
Multi-Walled Hydroformed Tubes
Multi-Walled Tubes
Laser Welded Finalized Tubes
Laser Welded Tube Profiled Sections
Broad Bandwidth of Manufacturing Options
Technology Portfolio
FSV Advance Manufacturing
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Trends in Lightweighting with AHSS
Source: WorldAutoSteel
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Today’s Steel Portfolio
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Challenges for ACES & Future Mobility
SAFETYFLEXIBILITY /
MODULARITY
TOTAL COST OF
OWERNSHIPDURABILITY RECYCLABILITY
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NPR 03.01.2019
Pedestrian Impact
Cybersecurity
Occupant Protection
Safety
https://www.npr.org/2019/02/28/699195211/pedestrian-deaths-reach-highest-level-in-decades-report-says
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← Steels for safety-critical parts, especially for maintaining a
passenger survival space in crash events
← High-strength steels with a good balance of strength,
formability, energy absorption and durability
← Steels with excellent formability (e.g., for deep drawing)
Improved Collision Performance
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Crumple Zones (engine
compartment, trunk) deform to
absorb energy and control
magnitude of deceleration
Passenger Compartment resists
deformation to prevent intrusion
Crashworthiness Fundamentals – Two Key Zones
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• Highest Energy Absorbing
• Strength AND Ductility
• Dual Phase and TRIP Grades PreferredTrue Stress - True
Strain
0
100
200
300
400
500
600
700
800
0 5 10 15 20
% True Strain
Tru
e S
tres
s (
MP
a)
HSLA 350/450
DP 350/600
TRIP400/600
Dual Phase and
TRIP are Higher
Energy Absorbing
Grades
Steels for Crumple Zone
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• Highest Strength
• Boron Hot Formed, Martensite, 3GAHSS
Steels for Passenger Compartment
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Ford F-150Alum. Section Height = 99 mm
Chevy Silverado Steel Section Height = 88 mm
Minimized Blind Spots
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Decreased Mass
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Stake Bead: B2H8
Top: KTBF1180
Middle: UDP980
Bottom: UDP590
Improved Formability and Styling
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Corrosion Protection
Lap Weld Coupons
Stamped Coupons
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A/SP Front Lower Control Arm Project
AHSS Stamped Clamshell design:
• Matches weight of forged aluminum baseline
• 34% lower mfg. cost at production of 250K vehicles per
year
• Lower life cycle greenhouse gas (GHG) emissions than aluminum
baseline
• Implemented on multiple vehicles
Cost Efficiency
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1197 kg1149 kg 1108 kg 1060 kg
Cost of Lightweighting
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Steel is the MOST recycled automotive material
Recycling
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What automakers & mobility providers need, steel is already
delivering today...
And fulfills consumer / user interest in mobility to improve the
quality of life
by streamlining the movement of people and goods
Safety/
CrashworthinessPerformance Durability / Reliability
Flexibility/ModularityPackage Space
Optimization
ManufacturabilityCost/Total Cost of
Ownership (TCO)
Emissions Efficiency
RecyclabilityPleasant Ride
experience
Environmentally
Friendly
Confidence and
Convenience
Image: WSJ.com
What Steel Delivers to Future Mobility
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Image: WSJ.com
B-Pillarless Design
EV Battery Packaging
Efficient Lightweighting
Supporting Value Chain with Forward Looking Innovation
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Thank You / For More Information
CONTACT:John CatterallVice President – Automotive
ProgramAmerican Iron and Steel
[email protected]
Image: WSJ.com
mailto:[email protected]
