Steel in Automotive Industry The View from the Supply Chain

Dr.-Ing. Hosen SULAIMAN, Klaus UNRUH

16 June 2015

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

3

34 countries

99,500 employees

€18.8 billion of total sales*

6,000 engineers and technicians

30 R&D centers

505 patents filed in 2014

330 sites

Automotive Seating Interior Systems Emissions Control

Technologies

Automotive Exteriors

Steel in automotive industry - METEC & 2nd ESTAD 2015 - 16 June 2015

Trends and challenges in the automotive industry

Steel in automotive industry - METEC & 2nd ESTAD 2015 - 16 June 2015 4

Expanded regulatory requirements

Globalization

Mega Platform, Standards Safety

Shift customer demand Demand on lighter car

Vehicle weight increased until end of 2000’s

Steel in automotive industry - METEC & 2nd ESTAD 2015 - 16 June 2015 5

1990 2010 1970

Vehicle unladen

weight (kg)

Time (year)

1300

1100

900

700

1980 2020 2000

Source: Auto evolution

Golf I

OEM forecast

Golf II

Golf III

Golf IV

Golf V

Golf VI

Golf VII

Other cars are following the same trend

2030+

Weight evolution over 7 VW Golf Generations

Renault Clio

Ford Fiesta

Peugeot (205 to 208)

VW Golf

Car weight split and the total target

Steel in automotive industry - METEC & 2nd ESTAD 2015 - 16 June 2015 6

1970 2000 2020

750 Kg Increase in vehicle dimension – longer, wider, taller cars

Improved Noise, Vibration, Harness & handling

Comfort systems – air condition, seats

Infotainment & other electrical systems

Emission treatment systems 1300 Kg

800 Kg

2010

Delta weight target: 500 kg (~40%)

Reference C segment car (Golf and equivalent)

Car weight

Target

Occupant safety such as airbags, pretensioner …

Performance systems for better acceleration, handling & braking …

Usage growth of AHSS in the automotive industry

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Source: Ducker Worldwide

Material family for cold forming process

Steel in automotive industry - METEC & 2nd ESTAD 2015 - 16

June 2015 8

2000

2010

2020

Higher Strength Steels require higher process expertise

higher strength level higher process effort

smaller process window

1990

1980

2030

Global supply chain, considering local suppliers

9 Steel in automotive industry - METEC & 2nd ESTAD 2015 - 16 June 2015

Complex Material Landscape with different standards

10

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)

ASTM – HSS, AHSS

• Focus on Yield Strength for HSS

• Tensile test length: 50 mm (ASTM)

Steel in automotive industry - METEC & 2nd ESTAD 2015 - 16 June 2015

ASTM

SAE

IRAM-IAS

EN

GOST

JIS

IS

GB JFS

NBR

OEM spec.

VDA 239-100 ?

Material Approval - Testing

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Material structure - grain size

- phase fraction analysis

- microstructure

- alignment

Mechanical properties - tensile testing

- anisotropy

- hardness

- folding

Chemical

composition - bulk element analysis

- carbon equivalent

Mechanisms

Frames

Scattering analysis strength - S355MC

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300

350

400

450

500

550

600

300 350 400 450 500 550 600

Tensile

str

ength

, M

Pa

Yield strength, MPa

S355MC (E-A)

S355MC (E-T)

S355MC (I-E)

S355MC (R-N)

S355MC (R-S)

S355MC (C-W)

Scattering analysis strength – “DP1000/ CP1000”

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800

900

1000

1100

1200

1300

500 600 700 800 900 1000 1100

Te

nsile

str

en

gth

, M

Pa

Yield strength, MPa

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)

CR550Y980T-DPCR700Y980T-DPCR780Y980T-CP

Material Approval - Statistical analysis

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Martensite

Evaluation of data

Scatter analysis

Flow curves for FEA

Important material data for product and process development

15

Edge

cracks

Bulge

Test

Work hardening

Stretch-ability

Failure criteria

FLC

Flow curve

Compression

Bend-ability

Yield

Loci

HHE

Aniso-tropy

Steel in automotive industry - METEC & 2nd ESTAD 2015 - 16 June 2015

Is the data sufficient for application?

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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

• ….

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

Future demand

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Required specific steel grade will depend on product and process design

Conclusion and Outlook

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• Safety

• Environment

• Globalization

• Lightweight

Automotive challenges

• Thickness reduction

• Higher strength material

• Formability reduction

• Higher scattering

• Local standard

Increase usage of AHSS

• Small process window

• No standardized testing method to evaluate process ability

• Different material standard / behavior

• Geometry complexity

Higher development complexity

Future priorities

• Close collaboration between steel

makers and users

• Standard method for characterization

• Specific process related testing

• Harmonizing the testing procedure for

better comparison

Thank you for your attention!