Dr.-Ing. Hosen SULAIMAN, Klaus UNRUH 16 June 2015 Steel in Automotive Industry The View from the Supply Chain
Agenda Introduction Current situation on steel usage and delivery Material approval and future needs Conclusion and Outlook Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 2
Faurecia Group 34 countries 505 330 patents filed in sites 2014 18.8 billion of total sales* 6,000 engineers and technicians 99,500 employees 30 R&D centers Automotive Seating Interior Systems Emissions Control Technologies Automotive Exteriors Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 3
Trends and challenges in the automotive industry Expanded regulatory requirements Globalization Mega Platform, Standards Safety Shift customer demand Demand on lighter car Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 4
Vehicle weight increased until end of 2000 s Weight evolution over 7 VW Golf Generations Vehicle unladen weight (kg) 1300 Other cars are following the same trend Golf VI VW Golf Renault Clio 1100 Golf IV Golf V Golf VII Peugeot (205 to 208) Ford Fiesta 900 Golf III OEM forecast 700 Golf I Golf II 1970 1980 2000 2020 1990 2010 2030+ Time (year) Source: Auto evolution Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 5
Car weight split and the total target Car weight 1300 Kg Emission treatment systems Performance systems for better acceleration, handling & braking Occupant safety such as airbags, pretensioner Infotainment & other electrical systems Comfort systems air condition, seats 800 Kg Improved Noise, Vibration, Harness & handling 750 Kg Increase in vehicle dimension longer, wider, taller cars Target Delta weight target: 500 kg (~40%) Reference C segment car (Golf and equivalent) 1970 2000 2010 2020 Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 6
Usage growth of AHSS in the automotive industry Source: Ducker Worldwide Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 7
Material family for cold forming process 1980 1990 2000 2010 2020 2030 higher strength level higher process effort smaller process window Higher Strength Steels require higher process expertise Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 8
Global supply chain, considering local suppliers Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 9
Complex Material Landscape with different standards ASTM HSS, AHSS Focus on Yield Strength for HSS Tensile test length: 50 mm (ASTM) EN HSS, AHSS Focus on Yield Strength for HSS but on Tensile Strength for AHSS Tensile test length: 80 mm (DIN) JIS HSS, AHSS Focus on Tensile Strength Tensile test length: 50 mm (JIS) GOST ASTM SAE EN IS GB JIS JFS NBR IRAM-IAS OEM spec. VDA 239-100? Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 10
Material Approval - Testing Mechanical properties - tensile testing - anisotropy - hardness - folding Frames Material structure - grain size - phase fraction analysis - microstructure - alignment Mechanisms Chemical composition - bulk element analysis - carbon equivalent Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 11
Tensile strength, MPa Scattering analysis strength - S355MC 600 550 500 S355MC (E-A) S355MC (E-T) S355MC (I-E) S355MC (R-N) S355MC (R-S) S355MC (C-W) 450 400 350 300 300 350 400 450 500 550 600 Yield strength, MPa Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 12
Tensile strength, MPa Scattering analysis strength DP1000/ CP1000 1300 1200 1100 1000 CR550Y980T-DP CR700Y980T-DP CR780Y980T-CP CR700Y980T-DP (E-S) CR780Y980T-CP (E-A) CR700Y980T-DP (E-A) CR780Y980T-CP (K-P) CR550Y980T-DP (C-B) CR700Y980T-DP (J-K) CR780Y980T-CP (E-V) 900 800 500 600 700 800 900 1000 1100 Yield strength, MPa Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 13
Material Approval - Statistical analysis Evaluation of data Scatter analysis Flow curves for FEA Martensite Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 14
Important material data for product and process development Work hardening Edge cracks Bulge Test Flow curve Yield Loci Failure criteria FLC HHE Compres sion Stretchability Bendability Anisotropy Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 15
Is the data sufficient for application? Unanticipated formability problems: No proven method to predict split in the extruded holes Cut edge stretching limit Split in compression area (luggage corner) is not predicted by FLC Bending radii, cracking limit. Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 16
Future demand AHSS with higher formability Common, extended testing procedures: Dome stretching, FLC total elongation Hole expansion local elongation Edge stretching local elongation Bending local elongation Compression Required specific steel grade will depend on product and process design Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 17
Conclusion and Outlook Increase usage of AHSS Automotive challenges Safety Environment Globalization Lightweight Thickness reduction Higher strength material Formability reduction Higher scattering Local standard Future priorities Close collaboration between steel makers and users Standard method for characterization Specific process related testing Harmonizing the testing procedure for better comparison Higher development complexity Small process window No standardized testing method to evaluate process ability Different material standard / behavior Geometry complexity Steel in automotive industry - METEC & 2nd ESTAD 2015-16 June 2015 18
Thank you for your attention!