Future Steel Vehicle Advanced Powertrains

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1 Future Steel Vehicle Advanced Powertrains and the influence on Material Selection Great Designs in Steel: May 13 th 2009 Harry Singh (EDAG FSV Program Manager)

2 Overview 1. Introduction: EDAG brief overview WorldAutoSteel, Sponsoring Companies 2. WorldAutoSteel Future Steel Vehicle (FSV) Advanced Power Tr rain Systems HEV, PHEV, BEV, FCEV Well to Wheels efficiencies FSV Materials Portfolio

3 EDAG - Overview In USA since 1994, 350 employees Product Development Engineering Services Styling Design & Engineering Computer Simulation

4 WorldAutoSteel Members WorldAutoSteel, the automotive group of the World Steel Association, continually explores steel innovation that demonstrates the value of steel to the automotive industry. WorldAutoSteel member companies from around the world pool global resources to deliver vital research that is central to effective steel automobile applications. ArcelorMittal - Luxembourg Baoshan Iron & Steel Co. Ltd. - China China Steel Corporation - Taiwan, China Hyundai-Steel Company - South Korea JFE Steel Corporation - Japan Kobe Steel, Ltd. - Japan Nippon Steel Corporation - Japan Nucor Corporation - USA POSCO - South Korea Severstal - Russia/USA Sumitomo Metal Industries, Ltd. - Japan Tata Steel & Corus - India, UK, Netherlands ThyssenKrupp Stahl AG - Germany United States Steel Corporation - USA Usinas Siderurgicas de Minas Gerais S.A. - Brazil Voestalpine Stahl GmbH - Austria

5 Future Steel Vehicle WorldAutoSteel continues to lead the materials revolution through projects like the Ultra Light Steel Family of Research: ULSAB, ULSAC, ULSASS (BIW, Closures & Suspensions) ULSAB-AVC (Advanced Vehicle Concepts) WorldAutoSteel s newest progra am Future Steel Vehicle (FSV) Part 1 Engineering Study (2008 July 2009) Part 2 Concept Design (July ) Part 3 Demonstration Hardware ( )

6 Future Steel Vehicle FSV Objective: Strengthen Steel s Position as the Automotive Structural Material of Choice for the Future Vehicles (2020) & identification of new applications for steel. FSV Justification: Global growth of vehicle fleet from 820,000,000 vehicles in 2008 to 1 billion by Transportation at present is 96% dependence e on petroleum. Daily worldwide petroleum usage 85,000,0000 barrels CO2 Vehicle emissions standards: EU 130 CO2 g/ /km 2009 & 95 g/km 2020, Japan 145 g/km 2009, USA CAFE 35mpg Increasing vehicle efficiencies to reduce petroleum consumption & to reduce Green House Gas emissions: are the key drivers for the implementation of Advanced Powertrains with increased focus on Vehicle Mass Reduction.

7 FSV: Phase 1 Engineering Study

8 FSV - OEM Direction/Trends The assessment of the announcements from automobile manufacturers show progress on various technologies which include; 1. Conventional internal combustion engine (ICE) based smaller more efficient gasoline/diesel vehicles 2. Higher efficiency Hybrid Electric Vehicle (HEV) 3. Plug-in hybrids (PHEV) with limited range of miles driven in Electric Mode. This option offer significant reduction in fossil based petroleum usage, especially when the daily distancess driven are close to the vehicle s electric range. The additional distance being driven using petroleum or Bio-fuels 4. Battery Electric Vehicles (BEV) with driving range of approximately 200 km 5. Fuel Cell Electric Vehicles (FCEV) using hydrogen gas as a fuel source

9 FSV - OEM Announcements A broad range of alternate propulsion vehicles have been announced by automakers around the world. The following table shows the number of vehicles announced by OEMs (Concept and Production) Future Steel Vehic cles Type BEV 18 PHEV - FCEV - Mitsubishi (2009) Subaru (C) Mercedes (2011) Th!nk (2009) BMW (2015) Tesla (2009) BMW (2009) Nissan (2010) NICE (2009) Dodge (2010) Toyota (2012) REVA (C) BYD(2011) TATA (2011) Ford (2011) Magna (C) OEM Announcements Electric only Plug-in Hybrid Fuel Cell GM (2011) GM (2010) Fisker (2010) Chrysler (2012) Toyota (2010) Mercedes (2012) BYD (2009) Volvo (C) Honda (2009) GM (C) Hyundai (C) Mercedes (C) (XXXX) Proposed year of production (c) Concept Vehicle

10 Future Advanced Powertrains PHEV (Plug-in Hybrid Electric Vehicle) Toyota Prius PHEV EREV (Extended Range Electric Vehicle) GM - VOLT BEV (Battery Electric Vehicle) Mitsubishi - I MiEV FCEV (Fuel Cell Electric Vehicle) Fuel Compressed Hydrogen Gas Honda - Clarity

11 Small Cars can be affordable, safe & fun, and HEV & BEV s TATA nano 3100mm 4 Occupants Daimler Smart for-two 2695 mm Toyota IQ 2985mm 3+ Occupants

12 FSV Fuel Cell Technology Assessment 70

13 FSV BEV Battery Technology Assessment kwh/kg

14 Petroleum to Li-ion Batteries? Approx 110 Wh (90 Wh for small car) of energy required per km of driving For small car 5 kwh battery driving range 32 km (year 2015 cost estimate $2,346) For mid-size car 12 kwh battery driving range 64 km (year 2015 cost estimate $5,400)

15 Vehicle Daily Distances Traveled USA Miles PHEV40 70% daily miles driven in Electric mode PHEV20 50% daily miles driven in Electric mode km Europe

16 FSV: Vehicle Size & Power Trains Worldwide over 70% market share between two vehicle sizes: Small car (up to 4,000mm, A/B class) and Mid-Class car (up to 4,900mm, C/D class) FSV 1 PHEV200 Electric Range 32km Total Range 500km Max Speed -150km/h km/h s BEV Total Range 250km Max Speed -150km/h km/h s FSV 2 PHEV400 Electric Range 64km Total Range 500km Max Speed -161km/h km/h s FCEV Total Range 500km Max Speed -161km/h km/h s Range based on UDDS cycle

17 FSV1: Occupants, Front & Rear Leg Room and Luggage Targets Occupants: Front Row Seating 2 Rear Row Seating mm 1065 mm Vehicle Class Average Front Leg Average Rear Leg Room Room A B C D Liters Luggage Liters

18 FSV2: Occupants, Front & Rear Leg Room and Luggage Targets Occupants: Front Row Seating 2 Rear Row Seating mm 1065 mm Vehicle Class Average Front Leg Average Rear Leg Room Room A B C D Liters Luggage Liters

19 FSV: V: Advanced Powertrains Concept Layouts FSV: BEV Battery Electric Vehicle FSV: FCEV Fuel Cell Electric Vehicle FSV: PHEV40 Plug-in Hybrid Electric Vehicle

20 FSV: Total Life Cycle Assessment (LCA) At present vehicle use (Pump to Wheel) Fuel consumption: km/l or CO2 g/km or mpg LCA: For Vehicle life of 200,000 km 1. Green House Gas CO2: g/km 2. Energy Efficiency: wh/km 3. Cost of Ownership: $/km

21 FSV: Efficiency of Fuels and Energy Sources Well to Pump Pump to Wheel Well to Wheel Gasoline Production 80 Gasoline % efficient 16 Diesel Production Bio Fuel: 84 Diesel % efficient units of energy Ethanol Diesel Renewable Internal Combustion Engine Electric Motor Drive Ethanol % efficient Bio-Diesel % efficient BEV Electricity Generation US-Mix 38 H2 - NG Reformation 62 Greet 1.8b Argonne National Lab FCEV

22 FSV1 - Pump to Wheel CO2 Emission g/km 7 Gasoline PHEV20 - CS PHEV20-500km PHEV20-150km Toyota Prius 2010 Pump to Wheel 100 kg Vehicle Mass Reduction 95 g/km 2020 EU 34 mpg, 14.4 km/l, 7.0 l/100km PHEV20-65km g/km 2012 EU PHEV20 32km CD BEV g/km 2009 JAMA (voluntary) CO2 Emissions in g/km CD charge depleting energy from battery CS charge sustaining energy from petroleum, similar to HEV

23 FSV: Electricity Production USA - Electricity Production Results also available for Europe, India, China, Japan, 100% coal, 100% Renewable [Source: Greet 1.8b US-Mix]

24 FSV1 - Well to Wheel CO2 Emissions g/km Gasoline 7 PHEV20 - CS PHEV20-500km Toyota Prius 2010 Well to Pump (US Mix Electricity) Pump to Wheel 100 kg Vehicle Mass Reduction PHEV20-150km 4 PHEV20-65km 3 PHEV20-32km CD BEV E50 J Electricity 100% Coal CO2 Emissions in g/km E50 Electricity Mix Europe J57 Electricity Mix Japan CD charge depleting energy from battery CS charge sustaining energy from petroleum, similar to HEV

25 FSV2 - Pump to Wheel CO2 Emission g/km Gasoline 8 PHEV40 - CS PHEV40-500km PHEV40-250km PHEV40-100km PHEV40 64km CD FCEV H2 - NG2 FCEV H2 - Elec Ford Fusion HEV 2010 Pump to Wheel 95 g/km 2020 EU 29 mpg, 12.5 km/l, 8.0 l/100km 100 kg Vehicle Mass Reduction 130 g/km 2012 EU 140 g/km 2009 JAMA (voluntary) CO2 Emissions in g/km CD charge depleting energy from battery CS charge sustaining energy from petroleum, similar to HEV H2 NG Hydrogen from Natural Gas H2 Elec Hydrogen from H2O Electrolysis

26 FSV2 - Well to Wheel CO2 Emission g/km Gasoline 8 PHEV40 - CS PHEV40-500km PHEV40-250km Ford Fusion HEV 2010 Well to Pump (US Mix Electricity) Pump to Wheel 100 kg Vehicle Mass Reduction PHEV40-100km 4 PHEV40 64km CD3 FCEV H2 - NG2 FCEV H2 - Elec CO2 Emissions in g/km CD charge depleting energy from battery CS charge sustaining energy from petroleum, similar to HEV H2 NG Hydrogen from Natural Gas H2 Elec Hydrogen from H2O Electrolysis

27 CO2 (g/km) Gasoline AT Gasoline CVT Gasoline MT Hybrid Diesel LPG FSV: Pump to Wheel CO2 g/km comparison ICE Hybrid PHEV20, CS Battery Charge Sustaining PHEV40, CS Battery Charge Sustaining PHEV, CD Battery Charge Depleting BEV Electric Vehicle FCEV Fuel Cell Vehicle Vehicle Mass (kg) FSV PHEV20 & PHEV40 70% Miles Driven in EV mode Energy from Electric Grid 30% Miles Driven in HEV mode Energy from Petroleum 27

28 Future Steel Vehicle Part 1 Engineering Study (2008 July 2009) Part 2 Concept Body Structure Design (July ) Part 3 Demonstration Hardware ( )

29 FSV: Phase 2 Concept Design Investigate the vehicles mass reduction potential with the use of Advanced High Strength Steel (AHSS), advanced manufacturing technologies and use of computer aided structural optimization. Understand the loads imposed by advanced powertrains on the vehicle structure and hence identify requirements for new grades of steel for optimized low mass vehicle structural applications and designs. 29

30 BIW (Kg) '01 - '03 Steel BIW ULSAB-AVC Aluminum BIW '04 - '08 Steel BIW Top 10 Steel BIW EU Super Light Car BIW Wt. vs. GVW FSV Body Structure Mass Targets Future Steel Vehicle Battery Electric Plug-in HEV Fuel Cell GVW (Kg)

31 Steel Grades for ULSAB (2000) Low Strength Steels (<210MPa) High Strength Steels Ultra High Strength Steels (>550MPa) Elon ngation (%) Mild BH 10 0 MART Tensile Strength (MPa) ULSAB Program: Achieved 25% reduction in BIW Mass 31

32 Steel Grades for ULSAB AVC (2004) Low Strength Steels (<210MPa) High Strength Steels Ultra High Strength Steels (>550MPa) Elon ngation (%) Mild BH 10 0 MART Tensile Strength (MPa) ULSAB ABC Program: Achieved 24% reduction in BIW Mass 32

33 Steel Grades Availability for FSV (2020) Low Strength Steels (<210MPa) High Strength Steels Ultra High Strength Steels (>550MPa) Elonga ation (%) Mild BH Tensile Strength (MPa) MART

34 Steel Grades Availability for FSV (2020) FSV Choice of Steel Grades 34

35 Manufacturing Processes ULSAB Manufacturing Techniques considered for the WorlAutoSteel ULSAB & ULSAB-AVC programs. 35

36 Manufacturing Processes FSV Manufacturing Techniques available (existing and emerging) that are being considered for the WorlAutoSteel FSV program. 36

37 Summary WorldAutoSteel Future Steel Vehicle (FSV) Advanced Power Train Systems PHEV20, PHEV40, BEV, FCEV Well to Wheels efficiencies FSV Materials portfolio Part 1 Engineering Study (2008 July 2009) Part 2 Concept Body Structure Design (July ) Part 3 Demonstration Hardware ( )

38 FSV Body Structure Mass Targets

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