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ULSAB-AVC – on the Road Today
Jody ShawAutomotive Center
United States Steel Corporation
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At GDIS 2002 we introduced ULSAB-AVC
74%
2%
10%4%1% 4%
1%4%
Dual Phase TRIP Mart ensit e Complex Phase Bake Hardenable High St rengt h IF HSLA Ot her
ULSAB-AVC• 25% Mass Reduction • Improved Crash Performance• At No Additional Cost
In 2002 the steel industry introduced ULSAB-AVC with significant claims of improvement performance with AHSS
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What have we done since then?E
long
atio
n (%
)
Yield Strength (MPa)
0
10
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0 400 600 1000200 800 1200
IF
MildIF
HSLADP, CP
TRIPBHCMn
IS
MART
Steel Grade Development
Since then the steel industry has been developing the grades needed to meet the promise
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Partnerships & Collaboration
What have we done since then?
We have been working though partnerships with directly with our customers to address the design and manufacturing challenges.
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What have we done since then?
Volvo XC90
Ford 500
Ford Mustang
Chevy MalibuJeep Cherokee
Honda Civic
BMW3 Series
GM Solstice
Porsche Cayenne
BMW X6
Vehicle ManufacturerProduct Development
Vehicle manufacturers have been incorporating these concepts into their products and we have seen the progress over the years at each GDIS event.
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So how far have we come?
74%
2%
10%4%1% 4%
1%4%
Dual Phase TRIP Mart ensit e Complex Phase Bake Hardenable High St rengt h IF HSLA Ot her
ULSAB-AVC• 25% Mass Reduction • Improved Crash Performance• At No Additional Cost
Has ULSAB-AVC been realizedin a production vehicle?
But have we been able to deliver on our promise?
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Has ULSAB-AVC been realized?
Basis of the Assessment
European Vehicle Data BaseTo answer this question – two data sets are utilized. The A/SP mass compounding study proposes a clear
relationship between BIW mass and GVW as a means of normalizing the BIW comparisons and the a2mac1 benchmarking data provides a look at this metric for 100+ European vehicles.
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Has ULSAB-AVC been realized?
The plot shows the typical performance of BIW at the time of ULSAB-AVC launch and confirms and even exceeds the magnitude of the 25% mass saving claim.
BIW Wt. vs. GVW
150
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250
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1000 1500 2000 2500 3000GVW (Kg)
BIW
(Kg)
'01 - '03 Steel BIWULSAB-AVC
27% Lighter than typical 2001 – 2003 BIW
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Has ULSAB-AVC been realized?
BIW Wt. vs. GVW
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200
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1000 1500 2000 2500 3000GVW (Kg)
BIW
(Kg)
'01 - '03 Steel BIWULSAB-AVCAluminum BIW
Aluminum BIW 39% Lighter than typical ‘01 – ‘03 BIW
Audi A2Audi A2
Audi A8Audi A8
Jaguar XKJaguar XKAudi TTAudi TT
The data also supports the 40% mass savings claim of the aluminum industry
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Has ULSAB-AVC been realized?
BIW Wt. vs. GVW
150
200
250
300
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1000 1500 2000 2500 3000GVW (Kg)
BIW
(Kg)
'01 - '03 Steel BIWULSAB-AVCAluminum BIW'04 - '08 Steel BIWTop 10 Steel BIW
Since then new vehicle launches have improved on the mass performance of the BIW. Focusing in on the top 10.
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Has ULSAB-AVC been realized?
The top 10 represent a broad range of vehicle classes and market segments. But have all been designed for the equivalent regulatory requirements and are all excellent performers
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Has ULSAB-AVC been realized?
BIW Wt. vs. GVW
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1000 1500 2000 2500 3000GVW (Kg)
BIW
(Kg)
'01 - '03 Steel BIWULSAB-AVCAluminum BIW'04 - '08 Steel BIWTop 10 Steel BIW
Advanced Steel BIWsare within 11% of a typical aluminum BIW
Vehicles have achieved the ULSAB-AVC mass targets
The data shows that many vehicle manufacturers are achieving the mass performance of ULSAB-AVC and closing the gap with the aluminum designs to within 11%. Some steel designs exceed the mass performance of aluminum.
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Increasing crash requirements
This is a remarkable achievement when we consider the significant increased performance burdens placed on the vehicle structure. However it is these requirements that have enabled the mass competitive of steel with aluminum, moving the structure from a stiffness controlled design to a strength controlled design – a criteria where steel excels
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
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2009 Jaguar XF Audi Q7
Aluminum stakeholder turning back to steel
Higher-strength and highest-strength steel
32%26%36%
Standard steel Aluminum High-strength
steel
Jaguar seriously considered using aluminum for the XF. But the XF will make considerable use of high-strength steel, which has come close to achieving aluminum's weight benefits at less cost” says Al Kammerer, product development director for Jaguar and Land Rover.AutoWeek| Published 01/16/07
BMW 7 Series
BMW will use all steel body structure on the next BMW 5 Series and 7 SeriesAutoTech Daily 3/12/09
BMW 5 Series
Vehicle manufacture with a previous strong stake in aluminum have recognized the value proposition of steel and are adjusting their product strategies accordingly.
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Prediction for the future
Future Launches
We predict that each new launch will follow this trend and it is clear that vehicle manufacturers will exceed the mass a reduction vision of ULSAB-AVC.
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But our work is not done
Global Fuel Economy Targets(normalized to CAFE – Converted to mpg)
2008 2010 2012 2014 2016 2018 2020
MPG
(Equ
ival
ent C
AFE
)
55
50
45
40
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30
25
20
EU
Japan
USA
California
2008 Current TargetsProposed Targets
Source - WorldAutoSteel FSV Program targets
Mitsubishi IMiev
Chevrolet Volt
Honda Clarity FCX Mercedes F cell
Mercedes E cell
Mercedes E cell Plus
The future fuel economy and CO2 emission requirements and the powertrains required to meet them will increase the demand for and value of mass reduction.
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But our work is not done
BIW Wt. vs. GVW
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1000 1500 2000 2500 3000GVW (Kg)
BIW
(Kg)
'01 - '03 Steel BIWULSAB-AVCAluminum BIW'04 - '08 Steel BIWTop 10 Steel BIWEU Super Light Car
EU SLC Materials
Steel36%
Aluminum53%
Magnesium7%
Plastic4%
EU SLC Materials
Steel36%
Aluminum53%
Magnesium7%
Plastic4%
37% Mass Reduction – 112% Cost Increase
Material competition continues and performance demands will continue to challenge steel role in the vehicle.
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But our work is not done
BIW Wt. vs. GVW
150
200
250
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450
1000 1500 2000 2500 3000GVW (Kg)
BIW
(Kg)
'01 - '03 Steel BIWULSAB-AVCAluminum BIW'04 - '08 Steel BIWTop 10 Steel BIWEU Super Light Car
Future Steel Vehicle• Battery Electric• Plug-in HEV• Fuel Cell
Future Steel Vehicle• Battery Electric• Plug-in HEV• Fuel Cell
The steel industry will continue to reinvent itself with new technologies and innovations to meet the requirements of the automotive industry. The WorldAutoSteel Future Steel Vehicle program will demonstrate these advances and
set new targets for the performance capability of steel in automotive designs.
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BIW Wt. vs. GVW
150
200
250
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350
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450
1000 1500 2000 2500 3000GVW (Kg)
BIW
(Kg)
'01 - '03 Steel BIWULSAB-AVCAluminum BIW'04 - '08 Steel BIWTop 10 Steel BIWEU Super Light Car
Future Steel Vehicle• Battery Electric• Plug-in HEV• Fuel Cell
Future Steel Vehicle• Battery Electric• Plug-in HEV• Fuel Cell
But our work is not done
Thank you
Questions?
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BIW Wt as a Percent of GVW
0%2%4%6%8%
10%12%14%16%18%20%
2001-2003Avg
ULSAB-AVC Steel Top 10 Aluminum Avg
%Addendum Slide
Relative mass values in this presentation are calculated from the average of each category and are as shown here.