Automotive Worldwide. S-in motion. Steel Saving weight Saving costs Sustainability Safety Service Strength Solutions

Transcription

1 Automotive Worldwide S-in motion Steel Saving weight Saving costs Sustainability Safety Service Strength Solutions

2 About ArcelorMittal ArcelorMittal is the world s leading steel company with operations in more than 60 countries. We are the leader in all major global steel markets, including automotive, construction, household appliances and packaging. ArcelorMittal operates some of the most technologically advanced steelmaking facilities and is an industry leader in research and development into new steels, coatings, solutions and services. The Company has access to sizeable captive supplies of raw materials and efficient global distribution networks. With an industrial presence in over 20 countries on four continents, ArcelorMittal services all of the world s key steel markets, from emerging to mature. Through our core values of Sustainability, Quality and Leadership, ArcelorMittal commits to operating in a responsible way with respect to the health, safety and well-being of our employees, contractors and the communities in which we operate. We are also committed to the sustainable management of the environment and of the world s finite resources. 2

3 What is S-in motion? S-in motion is a new concept for car makers who wish to create lighter, safer and more environmentally friendly vehicles for the 21 st Century. The project demonstrates ArcelorMittal s ongoing commitment to the automotive sector with a catalogue of steel parts and solutions that can be used to lighten production vehicles today. The catalogue currently includes multiple solutions for 43 parts of a typical C-segment vehicle. All of the solutions can be implemented in production vehicles today and help car makers to save weight and save costs, while providing sustainable, safe and strong vehicles. S-in motion further demonstrates ArcelorMittal s commitment to service in all stages of a vehicle s design and production process and its ability to develop solutions that meet the needs of today s car makers. The development of S-in motion was divided into two phases: 1. Module solutions i.e. front module, rear module, side module, closure module, etc. for North America and Europe 2. The lightest total vehicle solution for Europe S-in motion solution For most of the 43 parts, more than one solution has been identified. The resulting catalogue has over 60 solutions which utilise a range of different press hardened (PHS) and advanced high strength steels (AHSS), as well as stainless steel (typically 17.7C for the A-pillar lower outer) and long products (such as CRS2050 for the spring and forged SOLAMB1100 for the steering knuckle). Manufacturers who implement the lightest solution for each part could save up to 19% of the typical vehicle s weight (see table below) based on a comparison with a baseline C-segment vehicle. The study performed to take into consideration the more demanding North American rear impact and side impact requirements demonstrate that weight savings between 12 to 19% could be achieved for body side and rear modules. Potential S-in motion weight savings Baseline (C-segment) S-in motion Lightest Weight saved Saving (% baseline) Study scope % of baseline weight Saving (% scope) Body-In-White % % 19% Crash management system % % 10% Hang-on parts (closures & fenders) % % 17% Chassis % % 22% Total weight % % 19% 3

4 ArcelorMittal s automotive business ArcelorMittal s automotive business unit is a partnership-oriented organisation that supports its customers to expand and grow their businesses. We are the only maker of automotive steels that has a truly worldwide presence. That worldwide presence reflects the current nature of the automotive industry which is becoming increasingly globalised. The challenges faced by car makers are now common across the world, particularly with regard to environmental, safety and crash performance. ArcelorMittal is uniquely positioned to support global automotive companies in this competitive environment. Our automotive business unit is a focussed and flexible organisation that is designed to proactively respond to customer needs while optimising products and processes. ArcelorMittal customises its approach to each automotive customer, offering the product, engineering and service they require. Our customer support teams provide direct access to technical support, sales staff and our extensive supply chain and logistics networks where required. The challenges faced by car makers are now common across the world, particularly with regard to environmental, safety and crash performance. Key automotive business unit figures for 2010 and Revenue US$12.3 billion US$14.5 billion Flat steel deliveries 13.5 million tonnes 13.9 million tonnes Coated product deliveries 8.2 million tonnes 8.6 million tonnes 4

5 Saving weight with lighter and stronger steels Around 36% of the Body-In-White (BIW) of the baseline C-segment vehicle is made up of press-hardened steels (PHS) and advanced high strength steels (AHSS). Of this, PHS accounts for just 6% of the baseline BIW. In the optimised S-in motion solution, PHS and AHSS account for 54% of the weight of the BIW. While the level of AHSS remains almost constant, the amount of PHS in the vehicle increases to 25%. The study identified 29 parts of the S-in motion vehicle that could be made with hot-stamped Usibor 1500P steel (see illustration below). Cold- and hotstamped laser welded blanks (LWB) were identified as a solution for 24 of the S-in motion parts (see illustration below). Usibor was specifically developed by ArcelorMittal for hot stamping. At 1500 MPa, Usibor is one of the strongest steels used in automotive applications today. It also offers excellent performance in forming, joining and corrosion resistance. ArcelorMittal holds a number of patents for combining LWB and hot stamping. A highly innovative process, it enables car makers to make significant weight savings. For example, B-pillars can be produced that have a high level of strength in the upper part, but a lower level of strength in the lower part of the pillar. This enables controlled deformation in crash conditions, yet saves between 20 and 25% of the weight of a typical B-pillar. S-in motion is not just about saving weight. A conscious effort was made to ensure that the solutions identified were also safe, strong, and sustainable. As well as a Life Cycle Assessment (LCA), dent, crash and stiffness assessments were performed. Forming and assembly simulations and risk assessments were carried out before the industrial forming and assembly sequences were validated. Possible hot-stamped solutions Possible laser welded blank solutions 5

6 One face to the customer The pillar of ArcelorMittal s automotive organisation is our One Face to the Customer approach. Our dedicated customer teams are structured to support the worldwide growth of each of our customers, while providing local service. Each customer team is headed by a Global Account Manager who is in charge of the relationship between the customer and ArcelorMittal. They are supported by a Global Technology Coordinator who handles all technical issues. This two-person team is further supported by both regional and local sales and technical teams. With a complete range of commercial and technical expertise, each customer support team is designed to define and deploy the most appropriate product and service offering at both the global and local level. This flexible organisational structure enables ArcelorMittal to comprehensively meet the requirements of our customers. By fully matching our customers needs, ArcelorMittal brings exceptional value to their businesses. Our dedicated customer teams are structured to support the worldwide growth of each of our customers. ArcelorMittal s worldwide support structure for automotive clients 6

7 Sustainability: emissions decreased in production and use The LCA found that there was a 15% reduction in CO 2 eq emissions during the production of an S-in motion BIW. An LCA study was undertaken to determine the global warming potential of the BIW and closures of the S-in motion vehicle. The LCA found that there was a 15% reduction in CO 2 equivalent (eq) emissions during the production of an S-in motion BIW. This is largely attributable to the superior environmental properties of the PHS and AHSS steels used in the S-in motion catalogue of solutions. The baseline S-in motion car used for the LCA study had a typical lifespan of 200,000 km and fuel consumption of 6.6 litres/100 km. The results of the LCA showed that during the use-phase of the vehicles life, CO 2 eq emissions would be reduced by 13.5%. Combined with the savings during the production phase, that equates to a reduction of 1,749 kg of CO 2 eq for each S-in motion BIW. The savings translate to a reduction in CO 2 eq emissions of 6.2 grams/km for S-in motion vehicles. This is a significant saving for car makers who are under increasing pressure to reduce the weight of the vehicles. For example, European car makers face penalties if their vehicles exceed European Commission limits from The savings translate to a reduction in CO 2 eq emissions of 6.2 grams/km for S-in motion vehicles. Global warming potential of S-in motion BIW and closures kg CO 2 eq ,916 14% (1,749) 10,303 Ecobenefit Use phase Production + end of life phase Baseline Solution with power train resizing 7

8 Safety performance improved and tested The S-in motion car performed above industry standards, with most test results reaching or exceeding the highest AZT and Euro NCAP ratings. Crash test results A series of virtual tests were conducted to demonstrate the improved safety performance of the S-in motion car. Standard Euro NCAP and AZT crash tests were carried out to assess the effect of different types of impacts including rear crash, roof crush and side impact. AZT and Euro NCAP tests exceed minimum statutory safety requirements for new cars. The S-in motion car performed above industry standards, with most test results reaching or exceeding the highest AZT and Euro NCAP ratings (see table). Target Crash test Performance Euro NCAP Front crash On target Euro NCAP Pole crash On target Side crash (ECE R95) On target 5* Euro NCAP rating Rear crash On target Roof crush Above target Door crash (FMVSS214s) On target AZT AZT Danner (front and rear) On target 8

9 Stiffness test results Stiffness test Target Performance Result Static torsion 18,000 Nm/ 17,966 Nm/ Close/on target Static bending 12,000 N/mm 15,015 N/mm Above target 1 st Torsion >40.0 Hz 40.5 Hz Close/on target Stiffness optimisation was carried out on the S-in motion car and then evaluated using static load-case assessments. All relevant parts were tested, then optimised, and tested again to ensure they performed adequately. The results of the tests on final parts were at or above target values (see table). Modal analysis 1 st Vertical Bending >42.0 Hz 45.6 Hz Above target 1 st Lateral Bending >42.5 Hz 42.8 Hz Close/on target 9

10 Full range of metallurgical solutions ArcelorMittal s automotive steels cover all metallurgical families of steels. ArcelorMittal s automotive steels cover all metallurgical families of steels and offer a full range of compromises between stampability and weight reduction. We are a recognised technology leader in advanced high strength steels (AHSS), galvanised steels, and coated steels. Our long-term partnership with car makers enables ArcelorMittal to be in phase with the automotive market s expectations. For example, ArcelorMittal has been able to provide solutions for low-cost cars and engine powertrains, matching the strategies of car makers and market trends. ArcelorMittal s extensive experience in the automotive sector has led to the development of S-in motion which will enable our partners to meet future regulatory and consumer expectations for lighter vehicles. Quality is one of ArcelorMittal s core values and our automotive business unit is committed to this goal. Although we manufacture steel in more than 20 worldwide locations, our products have consistent mechanical properties and quality, wherever they are produced. Our products have consistent mechanical properties and quality, wherever they are produced. ArcelorMittal s global automotive presence 10

11 Formability and assembly validated Forming validation methodology Formability testing of the S-in motion parts was carried out using a gradual level of validation approach. This is a standard forming validation methodology used in the automotive industry. Both hot- and cold-stamped solutions were tested where appropriate. Experimental approach ArcelorMittal Methodology Incremental approach One-step approach Expert validation Hot stamping Hot stamping try out Hot stamping ArcelorMittal thermo-mechanical simulation Pamstamp incremental Autoform One-step Analogy Cold stamping Cold stamping try out Outifo springback control Autoform incremental Autoform One-step Analogy Assembly validation methodology The aim was to ensure all parts could be assembled without introducing weaknesses into the S-in motion vehicle. An assembly feasibility study, using ArcelorMittal s own methodology, included a risk analysis of welding combinations as well as tests on critical assemblies. Experimental validation Experimental weldability range and cross tensile tests Numerical validation via Sorpas Numerical weldability range Exhaustive assessment OEM acceptance criteria 11

12 Worldwide research and development centres that contributed to the S-in motion project ArcelorMittal s automotive business unit accounts for 25% of the company s total research and development budget which exceeds US$250 million annually. ArcelorMittal has a number of laboratories that research new products and processes for the automotive market. More than 600 engineers and technicians are employed in these facilities. ArcelorMittal s automotive business unit accounts for 25% of the company s total research and development budget which exceeds US$250 million annually. Our engineers work with car makers throughout the lifecycle of their products to develop new grades of automotive steels that are lighter, yet stronger than existing materials. New coatings are also developed to improve corrosion resistance, paint appearance and application processes. Our support begins in the early stages of a new vehicle s design and extends through to mass production and after-sales service. Our support begins in the early stages of a new vehicle s design and extends through to mass production and after-sales service. East Chicago (USA) Two hundred engineers and technicians are employed at ArcelorMittal s largest North American research centre. Automotive research focuses on structural design and computer aided engineering (CAE) analysis as well as the development and improvement of sheet-product applications and manufacturing technologies. Hamilton (Canada) Hamilton develops tube and sheet product applications for automotive. Structural design and CAE analysis are also carried out. Maizières (France) The larger of the automotive labs in France, Maizières Automotive Products is responsible for the development of new steel and the improvements of steels currently in use. The centre also researches anti-corrosion solutions, new coatings, breakthrough products and provides technical support to automotive customers. Montataire (France) Research at Montataire Automotive Applications focuses on the forming and design of automotive components and steel solutions. The lab also researches assembly, welding and adhesive bonding of multiple materials and laminates. Isbergues (France) The Isbergues research centre is dedicated to developing new stainless steel products, process and solutions. Around a quarter of the work at the lab is dedicated to automotive products including exhaust systems, and structural and decorative parts. Gandrange (France) 12 One of the main activities at the Gandrange R&D Centre is the market development of long carbon and wire solutions for the automotive market. The Centre also provides technical support to manufacturing plants and final customers, particularly in regard to process optimisation and product quality enhancement.

13 Cost-effective assembly proven PHS and AHSS grades are stronger, yet lighter, than traditional automotive steels. S-in motion BIW cost summary 2010 BIW Base Costs Baseline S-in motion Tooling amortisation 2% 3% Assembly 32% 34% Process 15% 18% Material 51% 45% Once the formability and assembly of the S-in motion vehicle had been proven, an industrial validation was performed in parallel with a cost analysis. The aim was to ensure an S-in motion car could be manufactured on an industrial scale and in a cost-effective way. Costs were calculated for the steel used in the part, processing of the material, assembly and the tooling required to create the part with a different type of steel. The comparisons (see table) showed that there was no cost increase based on 2010 prices for steel. This is because traditional steels that have been used for these parts require a thicker, heavier grade of steel. The newer PHS and AHSS grades used in the S-in motion parts are stronger, yet lighter, than traditional automotive steels. The S-in motion demonstrator A full-size S-in motion demonstrator has been constructed to show the various parts that have been developed during the project. This full-size S-in motion demonstrator provides car makers with interactive examples of the proposed solutions The demonstrator will tour a number of automotive events in Asia, Europe and North and South America and will be available for in-house roadshows at ArcelorMittal s automotive customers. 13

14 Cover Photography: Vezet route de Greucourt Mathieu Noel all rights reserved Copyright All rights reserved. No part of this publication may be reproduced in any form or by any means without prior permission in writing. Although care has been taken that the information in this publication is accurate, ArcelorMittal does not accept any liability for errors or omissions. Design Co-mana Communication Support Production Geers Offset ArcelorMittal 19, avenue de la Liberté L-2930 Luxembourg Version February 2012 You can download this brochure and find the most up-to-date info on 14

15 Further information about S-in motion ArcelorMittal will roll-out S-in motion to car makers through the company s worldwide customer teams and dedicated in-house road shows. You can find out more about S-in motion at or from your regular ArcelorMittal automotive contact. 15

16 ArcelorMittal Automotive Worldwide 19, avenue de la Liberté L-2930 Luxembourg EN S-IN MOTION - FEB. 2012