However, the prominence of ridesharing services and the advent of self-driving cars are rapidly changing the ways we move around, and according to experts, vehicle ownership will likely decrease.

Despite these challenging circumstances, however, worldsteel believes steel is not only relevant, but it’s also crucial for the development and innovation of future vehicles.

What advantages does steel have, and how can it help take POSCO’s neo-mobility concept even further? Let’s find out as POSCO Newsroom presents worldsteel, “Future Mobility Solutions Will Have Steel at Their Heart.”

As the world’s mobility systems undergo profound changes, providers will continue to be reliant on steel to help overcome a number of key challenges.

Automotive transport sits at a critical junction. Patterns of mobility and the methods of getting from A to B are shifting in response to disruption from new technologies and more sustainable approaches to resource management.

Operators are looking at the ways we move and the environments in which we do it. Vehicle ownership will likely decrease, with integrated ridesharing, sustainable methods of public transport and automated vehicles set to represent a larger proportion of journeys.

This change will have to be reflected in the infrastructure that supports these new methods of mobility. Specially designed street signs and architecture will help signpost journeys for automated vehicles, while the quality and predictability of our road surfaces will grow in importance.

Steel intensive technologies such as battery storage and integrated charging infrastructure for electric vehicles also represent a key enabling factor that must be addressed if the next generation of automotive transport is to achieve mainstream adoption.

Some providers have explored installing charging infrastructure in the roads themselves, with steel belts in the vehicle tyres and steel electrodes under the highway surface allowing for charging to take place while in motion.

l Reinventing the Wheel?

It is not just transport infrastructure that is changing, the essential design of automotive interiors and exteriors are being rethought in line with shifting ergonomic demands. These new vehicles will be more of a shared living or working space on wheels than a traditional car or van.

Renault’s EZ-GO concept comfortably allows for six passengers and with its batteries and engine placed under the floor of the vehicle and a panoramic glass roof design, it offers a ride experience that maximises exterior views and passenger comfort.

As automotive design becomes more aligned with that of interior and living spaces, the need to maximise the room available in vehicles without compromising on safety will only grow.

Also, as populations rise and car ownership is likely to decrease, ensuring public transport services are able to accommodate a rise in passengers is highly important. The need for more efficient and sustainable transport will inevitably lead to more people making journeys in a smaller number of vehicles.

l A Place for Steel

The rollout of automated transport solutions will bring a renewed focus on safety. Some concepts, such as the EZ-GO, will have capped speed limits to ensure safety, as well as light and sound displays for pedestrian awareness due to their silent running.

Even with these measures there will be a need for robust vehicle chassis in case of collision. Advanced high-strength steels (AHSS) can offer this protection without forcing automotive designers to compromise on panoramic views and interior comfort and adaptability.

The light-weighting advantages of AHSS will also be paramount as operators look to squeeze as much performance out of battery technology as possible. Lowering weight without compromising on safety will allow for extended maximum ranges for e-vehicles, with corresponding impacts on networks as charging stations can be more spread out.

Batteries will also require high levels of protection from collisions, with high-strength housings crucial as this allows for battery placement to be optimised for ergonomic considerations without impacting on safety.

High quality electrical steel will also help reduce core losses in e-motors, improving efficiency and boosting range. The extreme strength of new electrical steels means they are also able to withstand high levels of mechanical stress, extending the lifetime of the engine and allowing for smaller high-speed motors that save on space and weight.

The new wave of vehicles will bring a renewed focus on sustainability, safety and passenger comfort. It is clear that if future mobility systems are to overcome all three of these key challenges, then steel will play a key role.

Images: © Copyright Renault Group 2018

The original content published on the worldsteel’s ‘Our Stories’ section is available at: https://stories.worldsteel.org/automotive/future-mobility-solutions/

The Steel Recycling Institute (SRI), a business unit of the American Iron and Steel Institute, released a peer-reviewed study demonstrating the importance of material production emissions toward a vehicle’s lifetime environmental impact. The study, “Life Cycle Greenhouse Gas and Energy Study of Automotive Lightweighting,” examines the overall environmental impact of vehicle lightweighting using advanced high-strength steel (AHSS) compared with aluminum. The study demonstrates the importance of applying Life Cycle Assessment for accurate estimation of greenhouse gas (GHG) emissions.

What are the major findings of the study and what implications do they have for the steel industry? Find out at POSCO Newsroom.

In tandem with global efforts to curb greenhouse gas emissions, automakers and the steel industry have worked collaboratively to help with vehicle lightweighting while achieving the same high vehicle performance. Lightweighting with steel is possible because of new advanced high-strength steel (AHSS) grades replacing lower strength grades. Clearly, AHSS reduces the overall weight of the vehicles and boosts fuel efficiency, but what about its environmental impacts? Does AHSS aggravate or reduce the emissions of greenhouse gases?

The following five body structural materials were compared to access their lightweighting potential against GHG emissions.

<Material Production GHG Emissions for Common Body Structure>

▲ Material production GHG emissions for common body structure and closure materials accounting for estimated part mass reduction during the material production: 1 kg of mild steel potentially discharges 1.9 kg of GHG into the air – and a common body structure weighs about 100 kg, which means it will potentially release 190 kg of GHG into the atmosphere (Source: SRI)

For every 1kg of AHSS produced, it releases 1.9 kg of GHG into the atmosphere – however, its lightweighting capacity brings down the total amount of GHG released into the air. What about aluminum? The amount of GHG it produces per kg is much too high to benefit from its superb lightweighting capacity, raising the question of whether replacing steel is the best answer for the environment.

l Five Different Vehicles, Single Result

Based on the above comparison, it seems lightweighting with AHSS has the lowest GHG emissions. To fully evaluate this hypothesis, SRI conducted a comprehensive study to assess the total environmental impact of vehicles lightweighted with AHSS and aluminum. The study assesses the GHG emissions and energy consumption associated with the entire life cycle of a vehicle; comprising the vehicle production phase (including materials production), use (driving) phase, and end-of-life phase.

The study, “Life Cycle Greenhouse Gas and Energy Study of Automotive Lightweighting” assessed five different types of average consumer vehicles from 2016 model year in several size ranges and with different power train systems. They were: a mid-size sedan with a gasoline internal combustion engine; sport utility vehicle; pick-up truck; mid-size hybrid electric vehicle; and a compact battery electric vehicle.

These baseline vehicles were then each redesigned separately with aluminum and AHSS to reduce the overall weight while achieving the same general performance. Life cycle GHG emissions total and by individual phase were determined for each vehicle. One example of the model outputs is shown in Figure 2 for the SUV.

<Comparative Life Cycle GHG Emissions>

▲ Sample Graph from Study Showing Comparative Life Cycle GHG Emissions: The baseline vehicles, AHSS-intensive vehicles, and Aluminum-intensive vehicles went through comprehensive testing using LCA (Life Cycle Assessment) methods. AHSS-intensive vehicles had lower or equivalent total life cycle GHG emissions than aluminum-intensive vehicles for every class of vehicle tested (Source: SRI)

As expected, the materials production phase showed lightweighting with AHSS has the lowest GHG emissions. In the use phase with all else equivalent on a vehicle, the aluminum contender vehicle shows slightly lower emissions. Finally, in the end-of-life, credits are given to all materials because metals are melted again and put back into use, again aluminum is given a larger credit because it is so energy intensive to produce the primary metal. In total, however, the large increase in the production emissions for aluminum in the first phase of a vehicle’s life is often never fully recovered at the end of life.

l Aluminum: Light but Heavy

The details of the study’s methodology, assumptions, results, and multiple sensitivity and uncertainty analyses can be found in the full report, but the key findings and basic conclusions were:

(1) AHSS-intensive vehicles had lower or equivalent total life cycle GHG emissions than aluminum-intensive vehicles for every class of vehicle tested.

(2) The use of aluminum instead of AHSS to lightweight the vehicle body structure and closures resulted in a significant increase in materials production GHG emissions and energy consumption for every scenario. These emissions occur at the start of (and remain in the atmosphere throughout) the vehicle life cycle.

(3) In many cases, the dramatic increase in materials production emissions for vehicles lightweighted with aluminum instead of AHSS is never offset by emissions reduction benefits during the vehicles useful lifetime.

l AHSS Lowers GHGs by 12 Million Tons

So what do the results of this study mean in the real world? What does a kg of GHG emissions implicate? The model used for the SRI study calculates the difference in emissions per vehicle. When this number is multiplied by the number of vehicles produced in a given year of the vehicle type, the amount of GHG emissions becomes significant and representative of the real impact on the environment each year.

<GHG Emissions of Lightweighting Six Million Vehicles>

▲ AHSS results in lower GHG emissions over vehicle lifecycle based on lightweighting of approximately 6 million vehicles with primarily aluminum vs. primarily AHSS, as described in the Steel Recycling Institute study “Life Cycle Greenhouse Gas and Energy Study of Automotive Lightweighting.” (Source: SRI)

Lightweighting the five 2016 vehicle fleets with AHSS vs. aluminum would result in 12 million tons lower GHG emissions over their lifetime. This is equivalent to the GHGs emitted from consuming 1.2 billion gallons of gasoline.

Other equivalents for 12 million tons of  greenhouse gas include:

· 2,757 wind turbines running for an entire year
· The annual electricity production for 1.6 million homes
· 26.7 billion miles driven by an average passenger vehicle
· The amount of carbon sequestered annually by 12.8 million acres of U.S. forests

<Equivalents for 12 Million Tons of GHG>

▲ GHG equivalencies are from the EPA Greenhouse Gas Equivalencies Calculator (Source: SRI)

l “Steel Offers the Best Solution for the Environment.”

What does this mean for the environment? Compared to other materials, steel has the lowest greenhouse gas emissions making it the environmentally sound choice for automakers.

To meet the needs of today’s auto industry and its increasingly strict demands, POSCO has been working tirelessly to develop ideal materials. POSCO GIGA STEEL, the advanced high-strength steel (AHSS) produced by POSCO is one such effort. The name came from its tensile strength of over 1,000 (Mpa), an equivalent of one gigapascal. Because POSCO GIGA STEEL boasts high strength, it is possible to use less of it ultimately making it lighter than car frames made of general steel or aluminum. When compared to aluminum, GIGA STEEL is three times stronger yet three times lighter, costing 3.5 times less to produce and 2.1 times less to manufacture. When looking at the entire lifecycle of a vehicle made with steel, POSCO GIGA STEEL emits 10% lower CO₂ emissions.

“As driving emissions decrease to meet regulations, production emissions become an even more significant component of a vehicle’s full environmental footprint,” said Jody Hall, vice president, automotive market, Steel Market Development Institute. “If material production phase emissions continue to be overlooked, negative effects on the environment will begin before the vehicle is ever driven. Steel offers the best solution for the environment, the best performance and cost-effective solution for automakers, and ultimately the best value for consumers.”

The complete report of SRI’s “Life Cycle Greenhouse Gas and Energy Study of Automotive Lightweighting,” is available through an email request on the SRI website.

*Following completion, the study underwent independent critical review by a panel of automotive life cycle assessment experts. The panel verified the study confirms to the applicable ISO (International Organization for Standardization) standards for comparative LCAs, thus giving it a third party validation as a scientifically based study.

*Disclaimer (1): The views expressed are those of the Steel Recycling Institute and do not necessarily reflect the official policy or position of POSCO.
*Disclaimer (2): The part regarding POSCO GIGA STEEL does not reflect the official position of Steel Recycling Institute.

According to the 2018 survey by Steel Market Development Institute (SMDI), 75 percent of consumers regard safety as the most crucial factor in their decision to purchase or lease a vehicle. However, just because consumers prioritize safety, that doesn’t mean they want extra bulkiness added to their car. As automakers strive to build sturdy yet lightweight vehicles, steel companies are trying to match the automakers’ such demands.

To compare aluminum and steel, the two materials automakers widely use, aluminum is lighter than steel. That’s because aluminum is about half as dense as iron on the periodic table. However, when it comes to tensile strength, steel is about four times stronger than the strongest aluminum alloys available. This means, aluminum parts need to increase the thickness to meet safety standards, while advanced high-strength steel (AHSS) can be made thinner, thereby reducing the total weight.

Dr. Jody N. Hall, vice president of the automotive market division at SMDI says, “You may get lower mass with aluminum, but it’s a relatively small difference, and you pay for that mass reduction because of the higher cost of the material.” According to Dr. Hall, such factor may impact the driving experience, and if all the parts are the aluminum, it can also reduce the space efficiency of the vehicle’s interior.

Is there a material that satisfies consumers’ demand for both vehicle strength and lightweight intelligent design?

l Global Automakers, All Eyes on AHSS

AHSS is increasingly getting recognized as the material to satisfy such consumer demands. AHSS is stronger than the conventional automotive steel sheet – with AHSS, thinner steel sheet can be used compared to the conventional steel sheet, which enables automakers to build vehicles that are both strong and lightweight.

AHSS is usually applied as structural steel like side sills, which are typically installed at the bottom of the vehicle’s door to minimize external impact.

Many 2019-model vehicles introduced at the North American International Auto Show last month share one common attribute, which is advanced high-strength steel structure. AHSS was represented in the composition of various vehicle segments and sizes, including the popular SUV, CUV and truck markets.

2019 Ram 1500, the winner of the 2019 North American Truck of the Year, includes 54 percent AHSS in the truck bed and cab, and 98 percent in the frame. AHSS eliminated 45kg (approx.100 pounds) while gaining stiffness and durability of the frame, making the new 2019 Ram the strongest model thus far.

▲2020 Toyota Corolla (SOURCE: 2019 Detroit Auto Show)

As for the 2020 Toyota Corolla, the increased use of AHSS enhanced body rigidity and occupant safety. The torsional rigidity is improved by 60 percent than its predecessor. 2019 Subaru Forester applied 31 percent AHSS for long-lasting quality, enhanced crash safety, and a quieter interior.

▲2019 Jeep Cherokee (Source: Detroit Auto Show)

To achieve lightweight in the body, 2019 Jeep Cherokee used 65 percent hot stamped, high-strength steels and AHSS. In addition, thanks in part to the AHSS used in the body, the 2019 Mercedes-Benz G-class lost 170kg (approx. 375 pounds). Steel aided in rigidity and load-bearing functions of the vehicle.

More than 65 AHSS-intensive vehicles debuted at major auto shows across North America in 2018 and in the NAIAS 2019, achieving lightweight in the body, higher tensile strength, and durability.

l Giga Steel, Light but Strong

Source: Detroit Auto Show

Industry expert consensus is that, with global regulations on automobile safety and CO2 stronger than ever, automakers’ inclination toward lightweight vehicles is inevitable. As automakers’ investments increase towards the future modes of transportation such as autonomous and electric vehicles, the key to successful investment is securing strong, durable, and cost-effective materials.

In the era of smart cars like electric cars and autonomous vehicles, POSCO has focused on developing future materials like Giga Steel. POSCO’s Giga Steel can significantly reduce the weight of automobiles.

POSCO’s Giga Steel is the next-generation steel plate that withstands the weight of 100kg per 1㎟ width. Its tensile strength is more than 960 MPa, which is equal to 1 Gigapascal, and that’s how POSCO Giga Steel came to be.

More specifically, a sheet of Giga Steel (10cm x 15cm) can withstand the weight of 1,500 mid-sized cars, each weighing one ton. Not only is Giga Steel three times stronger than aluminum, it also has excellent modability, making it an ideal material for constructing sturdy car frames.

*POSCO defines a steel sheet with a tensile strength of 780 megapascals (MPa) or higher as advanced high strength steel; Giga Steel has a tensile strength of 980 Mpa (1 Gigapascal) or more withstanding a load of 100 kg per square millimeter.

POSCO successfully created materials that are both sturdy and moldable, like TWIP steel and PosM-XF.

POSCO will use Giga Steel to curb the spread of steel-substitutes like aluminum and carbon fiber reinforced plastics (CFRP), solidifying steel’s position as the future material.

The North American International Auto Show 2019 demonstrated that the demand for stronger and lighter automotive steels will continue to expand. Dr. Hall of the SMDI reiterated that AHSS is “the best choice for automakers, suppliers, and consumers” because of its strength, durability, and cost-effectiveness. Along with the AHSS, Giga Steel is likely to be applied more widely in the global auto market.

Self-driving vehicle is a new trend for automotive industry(Source: TESLA)

Transformation of future automotive industry

The automobile industry is undergoing dramatic changes, including the rapid expansion of autonomous cars and stronger environmental regulations. Automakers are jumping into the autonomous driving market with the rise of ride sharing services, such as Uber and Didi, and vehicle ownership quickly becoming an option rather than mandatory. Additionally, with regulations on emissions continuing to tighten, automakers are viewing fuel efficiency and reducing emissions as priority mandates for future sustainability. These shifts in the auto industry are also driving other changes, such as how manufacturers are designing vehicles.

Electric car sharing is beneficial for both individual and society by saving transportation fee and lowering carbon emission(Source: La Valdichiana)

The key value proposition of autonomous vehicles is to be ‘user-friendly’, compared with traditional ‘driver-friendly’ vehicles. While the main function of automobiles as a transportation mode has not changed, the concept of how to offer a convenience-oriented experience to the automobile user is undergoing remarkable innovation. In this context, steel will factor crucial as the primary material of the next generation of automotive.

Material production will be fundamental

As future user-oriented automotive will require more battery power, automakers will need to identify a method to implement more batteries in their vehicles. The issue, however, facing automakers is battery capacity improvement is limited. The more batteries, the heavier the car. As example, electric cars are much heavier than gasoline or diesel cars because of the weight of batteries.

To address this, automakers are investing in solutions to increase battery capacity while maintaining a low vehicle weight. Lower vehicle weights are also mandated by new environmental regulations as lighter cars lead to lower fuel consumption. In order to reduce fuel consumption through technological developments, automobile manufacturers are suggesting to reduce the weight of the car’s body, while still ensuring safety, through utilization of special materials.

“In the near future, there will not be substantial improvement in battery capacity and in battery power. This means we have to put more batteries in the car. So Lightweight design is mendatory” – Ingo Olschewski, fka, Germany

Material used on vehicle frame will decide the success of manufacturing lightweight vehicle(Source: Compositespress)

Material production, in specific, will be increasingly fundamental as the ideal method for maximizing lightness, with alternative materials such as AHSS, magnesium, aluminum, and plastic anticipated to take the spotlight.

Steel still primary for the future

As the market for autonomous cars continues to rapidly expand, automakers will require more steel than before. The design flexibility of steel offers diverse benefits for automakers, such as higher formability. With steel, automakers can develop more complex designs for users, and autonomous car manufacturers are able to maximize on safety and cost with steel’s inherent advantages.

Going forward, it is anticipated that the development of lightweight materials centered on ultra-high-strength steel sheets will be expanded, with steel continuing to serve as the primary material for the automotive industry.

Steel is still considered as primary materials for manufacturing future vehicle(Source: AutoComponentIndia)

Unlimited potential of steel, AHSS

Among different steel products, Advanced High-Strength Steel (AHSS) is a complex, advanced material, with careful chemical composition and multiphase microstructures resulting from precisely controlled heating and cooling processes. For reasons from its lighter weight to strength to design flexibility, AHSS promises to serve as a key alternative source for future vehicles.

In terms of weight, AHSS is more effective than aluminum when it comes to making cars lighter. A vehicle body weight of 250 kilograms can be reduced to 218 kilograms with AHSS. In 2012, POSCO developed its own PBC-EV (POSCO Body Concept Electric Vehicle) body applied with POSCO GIGA STEEL, resulting in a 26.4% weight reduction compared to an existing body of the same size.

GIGA steel provides huge improvement of manufacturing vehicles in terms of strength and lightweight

While an AHSS sheet weighs less than a regular steel plate, it has twice the strength. In particular, GIGA STEEL received its name for its tensile strength greater than 1 GPa (Giga Pascal), meaning it can withstand more than 100 kilograms-force per square millimeter.

POSCO GIGA STEEL falls within the strongest categories of steel available to auto manufacturers today. Usually applied to timber, outer plates, and reinforcement, when AHSS is applied to automobiles, the result is a vehicle body as equally lightweight as aluminum while also strong and safe.

Along with the universalization of autonomous cars, further environmental regulations will raise requirements for innovative automotive design. Steel has been indispensable in the automotive industry for more than a century, and will continue to remain so as the primary material utilized for automotive vehicles in the future, as solutions like AHSS lead the way.

Vehicle industry is entering evolutionary phase(Source: DS&F)

Trend of Future Mobility

One of the most competitive fields in the world, the automobile industry is currently eyeing two major issues in car body development: passenger safety and fuel efficiency. Competition is fierce between automakers to develop improved technology to make car bodies lighter, thus maximizing fuel efficiency and safety. The introduction of new environmental regulations as well as growth in popularity of electric vehicles has further thrust this focus on lightweight, high fuel-efficiency vehicles into the limelight.

What resources can be recommended for future frame of vehicle(Source: AutoTrend)

Then, what resources would be considered for manufacturing future automotive frame?

In the development of lighter vehicle bodies, steel still remains as an ideal option for the future of automotive frames. In fact, as new steel materials with higher strength capacities and lighter weights continue to be developed, other materials such as aluminium are being left behind due to certain drawbacks.
The future of steel is expected to deliver even lighter yet stronger designs, thereby further reducing a vehicle’s carbon footprint. In line with this trend, and with its unique strengths in durability and weight, AHSS as an alternative material in vehicle frame development has become a particularly hot topic in the industry.

Innovative technology make it possible to manufacturing eco-friendly frame(Source: MadeInAlabama)

Lighter for Green Society

Automakers are making significant investment in cutting edge research to discover technologies that reduce vehicle weight. This ensures they are effectively responding to the global trend of increasing standards for fuel efficiency, with a lighter weight the most effective method for improving car fuel efficiency.
Specifically, when vehicles are 10% lighter, fuel efficiency rises by 3.2%. In addition, acceleration performance increases by 8.5%, steering capability is 19% more effective, durability, 1.6 times higher, and carbon dioxide emissions are reduced by 3.2%.
Statistics like these back why steel should be considered as a future material for manufacturing vehicle frames, and for its part, AHSS shows impressive results when it comes to reducing carbon emissions.

To elaborate in more detail, the choice of material for even the same automotive part can have substantially different environmental impact, which can offset any weight benefit the specific material might offer. While there have been debates in the past about the best lightweight material, almost every car showcased at the North American International Auto Show (NAIAS), including the 2018 Car of the Year, was clad in AHSS and significantly lighter than its predecessors.

For example, the all-new 2019 Chevy Silverado comes armed with plenty of steel, with 80% of the vehicle consisting of a higher-grade alloy in the roll-formed, AHSS bed floor. This makes the bed more functional and lighter in weight, resulting in a 450lb/204kg weight reduction. Overall, while the all-new Silverado is taller and seven inches wider than before, it is also 450 pounds lighter with a 10% increase in torsional rigidity compared to the previous model.

Dodge Ram showed outstanding performance with AHSS

In another example, the 2019 Dodge Ram 1500, which was also unveiled at NAIAS, utilizes 54% AHSS in the truck bed and cab, and 98% in the frame. The use of AHSS helped to give the Dodge Ram a 225lb reduction in weight, along with a fuel efficiency increase of 25%, and 20% towing capacity improvement.

Future vehicle is required to be lighter and even stronger(Source: GreenCarReports)

Lighter and even Stronger

While car bodies need to be lighter to improve fuel efficiency, durability can be affected if the body is made too thin. In terms of safety, durability, and weight, AHSS, is helping the car to evolve.

Steel has proved itself to be competitive materials for future vehicle(Source: StarHaus Mercedes-Benz)

“The higher, the yield strength, the higher, the tensile strength. Due to its unique character, steel can absorb higher energy in a crash.” — Kenji Nishimura, JTE STEEL

A key reason why the automobile industry continues to focus on steel products is due its strength, and with ongoing advancements, the strength of steel has increased from 270 MPa over the past 20 years to about eight times the strength of 1 MPa, which can withstand 10 kg per ㎠.

AHSS(Advanced High Strength Steel) may show us the right passage for the future vehicle(Source: Arcelormittal)

According to Kia Motors America, the structure of the all-new Kia Sportage is significantly improved due to the extensive use of AHSS. With 51% of the Sportage’s body-in-white consisting of AHSS versus the outgoing model’s 18%, torsional rigidity has improved 39%. Plus, the structure of the 2019 Kia Forte redesign includes 54% AHSS, improving safety and increasing torsional rigidity by 16%.

“Steel is a single metal which can be designed to suit all combination of requirements. That is what makes steel so unique.” — Kinshuk Roy, JSW Steel Limited, India

With ongoing and rapid improvements in both weight and strength, steel is figuring predominantly into efforts to manufacture future high-quality vehicle frames, as well as bringing new life to the automotive industry to allow it to continually thrive in the future.

The 2018 North American International Auto Show brought the biggest names in the auto industry together for a show and tell. (Source: News Atlas)

Continuing on what we saw during the past few years, the focus this year again was on improving safety, performance and design, all at the lightest weight possible for fuel economy. While there have been debates in the past about the best lightweight material, there was a clear winner at this year’s NAIAS. Almost every car, including the 2018 Car of the Year, was clad in advanced high-strength steel (AHHS) and significantly lighter than their predecessors.

Take a look at some of this year’s steel-clad cars.

SEE ALSO: 5 Reasons Why AHSS Tops the Market for Lightweight Auto Materials

2018 Car of the Year: Honda Accord

The 2018 Honda Accord took home the prestigious title of Car of the Year due to its lightweight and improved strength and performance. The 2018 model contains 29 percent ultra-high-strength steel (UHSS) in its chassis and 54.2 percent high strength steel (HSS). With these applications, the Honda Accord achieved a weight reduction of 110 to 176 pounds while improving its body torsional rigidity by 32 percent and its bending rigidity by 24 percent.

2019 Chevy Silverado

The all-new Chevy Silverado comes armed with plenty of steel. One of the features that contribute to its improved safety is the bed floor made of roll-formed HSS. Also, 80 percent of its fully-boxed steel frame is made of HSS and AHSS forms the Silverado’s safety cage. Overall, the new model is taller and 7 inches wider than before. Nevertheless, the all-new Silverado is 450 pounds lighter with a 10 percent increase in torsional rigidity than the previous model.

2019 Dodge Ram 1500

The 2019 Dodge Ram 1500 is another steel-intensive vehicle revealed at NAIAS. About 98 percent of this year’s model is made from HSS, and is the lightest, longest and most efficient frame in the half-ton truck segment. The wheelbase and crew cab is 4 inches longer than the previous model. The Dodge Ram 1500 also has several new safety features. The unique front-splayed frame rail technology, frame-mounted HSS tire blockers and fully-boxed side rails allow the car to absorb more energy in case of impact and minimize structural damage.

2019 Kia Forte

The 2019 Kia Forte is taller, wider and longer than before with 54 percent of its chassis made of AHSS. It also has a 16 percent stiffer body-in-white and the new seat frames are lighter yet stronger as Kia has its eyes on top ratings from the Insurance Institute for Highway Safety (IIHS) for the second consecutive year. The lighter and stronger vehicle will consume about 9 to 20 percent less fuel as well as drop noise levels by 5 decibels.

Why the Steel Overload?

As mentioned above, the latest cars are steel-intensive and automakers increasing the amount of HSS, UHSS and AHSS in their mix of materials. Of course, the main reason for this is steel’s innate properties that make it the ideal solution for automakers looking to cut back on weight and still satisfy safety standards. However, automakers also learned a good lesson from automakers who chose another popular lightweight material – aluminum.

SEE ALSO: Materials Matter: Why Steel Beats Aluminum in the Sustainability Debate

Back in 2014, Ford released its F-150 with an all-aluminum body. The move was bold and the cars sold fast as it was a whole 700 pounds lighter than previous models. Consumers got to drive away with a drastically improved fuel economy, but it didn’t take long for them to realize the big, expensive problem with aluminum bodies: repairs.

The 2015 Ford F-150 has an all-aluminum body. (Source: Hennessey Performance)

Although steel and aluminum are similar in terms of its lightweight properties, aluminum reacts differently than steel under heat. Aluminum does not have metal memory, while steel does, making it hard to reshape and repair following an accident. Welding aluminum also takes much more skill and precision than steel, and there are few repair shops that are equipped to handle aluminum. As a result, drivers not only have a hard time finding repair shops for their aluminum cars, they have to pay a hefty price for repairs compared to repairs for steel cars. For example, Jalopnik reported one of the first cases of the F-150 repairs back in 2015 cost USD 17,000 and a month-long repair time.

Of course, this was a rare case highlighting the steep learning curve of repairing aluminum vehicles, but it also highlights the fact that steel is still the norm when it comes to automotive materials, and judging from the 2018 NAIAS, it’s going to stay that way for quite some time.

Cover photo courtesy of Honda of Lincoln.

Smart factories are bringing AI, IoT and Big Data to the manufacturing industry.

#1 How Smart Factories are Changing the Manufacturing Industry

The Fourth Industrial Revolution is bringing AI, IoT and other automated technologies into people’s lives and changing the way they live and interact with one another. It is also bringing about change in the manufacturing industry as more companies embrace smart factories to further enhance efficiency, performance and safety. Take a deeper look at how smart factories are reinventing the manufacturing industry.

SEE ALSO: How Factories Produce Steel- the Smart Way

POSCO GIGA STEEL also offers electric vehicle manufacturers a lightweight material solution.

#2 POSCO GIGA STEEL Increases Strength, Improves Safety in Autos

This year, POSCO GIGA STEEL set a new, industry standard for strength and formability for auto steel. The advanced high-strength steel (AHSS) is an automaker’s dream come true as it falls into the strongest category of steel commercially available today. Plus, its lightweight property makes it the perfect solution for manufacturers trying to design safe, high-performing and sustainable vehicles.

SEE ALSO: Ask an Expert: Has Steel Achieved Its Peak in Lightweighting?

Lithium-ion batteries are found in some of the most popular devices available today. (Source: BGR)

#3 POSCO’s Innovation Shapes the Ever-Growing Lithium Market

POSCO is the world’s 5th largest steel producer, but it’s got more up its sleeves than just steel. This year, POSCO developed game-changing technology that extracts lithium from water in just 8 hours to one month. Traditionally the task takes anywhere from 12 to 18 months. To add, the new technology can achieve a purity rate of 99.9 percent and increases the lithium recovery rate to over 80 percent.

Lithium is a central component in rechargeable batteries for electronics such as smartphones, laptops and most importantly, electric vehicles (EVs). Heading into 2018, POSCO is well-positioned to be an industry leader in a rapidly-growing market for EV batteries.

SEE ALSO: The Fuel of Tomorrow: Mining Lithium for Tomorrow’s Cars

POSCO CEO Kwon Ohjoon fires up Pohang Blast Furnace No.3

#4 POSCO Gets “Smart” with Pohang Blast Furnace No.3

In June, one of POSCO’s oldest and the world’s 5th largest blast furnace got a makeover with some added AI. After undergoing 102 days of repairs, Pohang Blast Furnace No.3 came back much bigger with an expanded furnace volume of 5600㎥, compared to its original volume of 3795㎥ from its beginnings in 1978. Plus, Pohang Blast Furnace No.3 now has smart sensors to monitor operations and detect malfunctions or accidents before they happen.

SEE ALSO: How to Make Steel with an Old(ie but Goodie) Blast Furnace

Ajay Telrandhe in Quality Assurance and Manish Kochar & Chetan Waghchoure in Sales talk to the Steel Wire.

#5 Ask an Expert: POSCO Leads India’s Growing Automotive Steel Market

POSCO Maharashtra is POSCO’s leading subsidiary. Three of their employees gave the Steel Wire an insider’s look into the company’s success, despite a challenging market environment and government restrictions. The team in India implemented positive changes in the company’s steel quality, production processes and customer service to become a leading solution-provider for their automotive partners.

SEE ALSO: Revving Up for Growth: India’s Automotive Market is In Full Gear

EVs, autonomous vehicles and shared mobility will drastically change the auto industry. (Source: Electrek)

#6 Ask an Expert: Electric Vehicles and the Future of the Automotive Market

Stephen Zoepf, executive director at the Center for Automotive Research at Stanford University, was the first speaker at POSCO’s 2017 Global EV Materials Forum. Zoepf shared his vision of what the future automotive market will look like and its implications for car manufacturers, suppliers and drivers. According to research, 60 percent of the cars in the U.S. will be running on electric batteries by 2030, and those cars will mostly be part of a shared mobility service. Traditional ways of car production, distribution and consumption will undergo massive change and companies will have to find ways to stay competitive in the new market dynamics.

SEE ALSO: The Forgotten Fleet: Looking Back on Early Electric Vehicles for a Better Future

Steel dresses from Naim Josefi’s 2017 F/W GANGS collection. (Source: Naim Josefi)

#7 Ask an Expert: Fashion Forward with Steel

Fashion designer Naim Josefi opened new possibilities for steel application with his 2017 F/W GANGS collection which included dresses made of elaborate steel sequins and laser-printed jeans. He is also known for his 3D-printed high heels that provide the perfect fit. The artist has a passion for fusing technology into his work and finding more sustainable ways to create beautiful clothes and says he will continue to use steel as a high-tech, fashion material.

Heading into a new year in 2018, the Steel Wire promises to be the best source of steel industry news and continue to provide exclusive, insightful and interesting stories.

More and more automakers are adding EVs to their fleet. (Source: Engineering and Technology)

While all this sounds promising for the environment, EVs don’t automatically translate into lower GHG emissions. According to World Auto Steel (WAS), the emissions from vehicle production will be greater than the amount of emissions from driving. As such, it is becoming increasingly important for manufacturers, policymakers and consumers alike to view material options by considering its life cycle assessment (LCA).

World Auto Steel Case Study

WAS conducted a case study in which they compared two popular lightweight materials for EVS; aluminum and Advanced High-Strength Steel (AHSS). The study followed the University of California Santa Barbara Automotive Energy & GHG Model (UCSB Model) for a comprehensive analysis of each material’s total energy use throughout its entire life cycle, from production to end of life recycling. For the study, WAS examined 1,000,000 BEVs of equal range that were made up of either entirely aluminum or AHSS.

BEVs made of AHSS require over 15 percent less energy than aluminum cars. (Source: World Auto Steel)

The study found that automakers can make over 17 percent more BEVs made of AHSS than aluminum BEVs with the same amount of energy. In other words, with the energy it takes to make 1 million aluminum BEVs, automakers can make 1.17 million AHSS BEVs.

Why is AHSS More Energy Efficient?

Aluminum production requires 8 times more energy per kilogram than steel production because the production process of aluminum is much more complicated and involves more steps than steel production. The aluminum BEVs in the study used up 30 percent more energy than those made from AHSS throughout its entire life cycle. Plus steel is 100 percent recyclable and can be reused almost indefinitely.

There are many sources of emissions output involved in the entire life cycle of a vehicle. (Source: World Auto Steel)

This poses a serious need to reexamine existing policies and regulations that only seek to reduce tailpipe emissions. By also taking into account emissions from the production of materials all the way to how a car is disposed at the end of its life cycle, automakers can grasp a better picture of the real impact of their choices on the environment.

A Sustainable Choice

As a solution-providing partner for automakers, steelmaker POSCO designed the perfect AHSS for cars that is lightweight, extremely strong, highly formable and environmentally friendly. POSCO GIGA STEEL belongs to the highest category for tensile strength of greater than 1GPa (Gigapascal). It can withstand more than 100 kg of force per square millimeter, making it 3 times stronger than aluminum. It is also 3.5 times cheaper than aluminum and 2.1 times cheaper to manufacture.

SEE ALSO: Infographic: Driving the Future with POSCO GIGA STEEL

POSCO GIGA STEEL is three times stronger than aluminum.

In 2016, POSCO sold 9 million tons of steel sheets for cars, making up 10 percent of the entire global automotive market for steel sheets. POSCO GIGA STEEL was designed to further improve the performance and efficiency of POSCO’s auto partners around the world. As the auto industry heads towards a future where environmentally-friendly EVs become the norm, POSCO will strive to equip its auto partners with the materials and tools necessary to stay ahead and competitive.

POSCO hosted the 2017 Global EV Materials Forum at the Songdo Global R&D Center in Incheon.

POSCO welcomed more than 380 local and overseas customers to the forum where they announced the current status of POSCO Group’s EV projects and strategies. The company also showcased its core EV technologies for high-value-added products such as motors, batteries and lightweight chassis/bodies.

During the forum, POSCO highlighted customer needs, market trends and development statuses in three areas: lightweight materials, traction motor cores and batteries. POSCO researchers also gave presentations on POSCO’s high-value-added products and solutions to share market insights and technological developments with the participants.

Participants listen to presentations at the 2017 Global EV Materials Forum.

In his keynote speech, In-hwan Oh, president of POSCO, said, “POSCO is in full preparation for the future of an electric vehicle ecosystem, to become a reliable partner to our customers.”

There were also external speakers at the forum, including Stephen Zoepf, Executive Director of the Center for Automotive Research at Stanford University, who spoke about “Electric Vehicles: Adapting to a Changing Marketplace.” Another external speaker was Martin Woehrle, senior director of BMW Korea, who gave a presentation on the trends in EV development.

In addition, POSCO held a separate exhibition at the venue consisting of four key product zones: motors, batteries, light-weight chassis/bodies and charging infrastructure. There was also an EV model on display in the Highlight Zone for a better understanding of the structure of EVs.

Visitors examine the electric Nissan Leaf

On display In the lightweight chassis/bodies exhibition zone was POSCO GIGA STEEL for lightweight chassis/bodies, which is lighter but much stronger than existing automotive steel sheets. Also on display was POSCO’s lithium materials for EV batteries; POSCO is the first company in Korea to commercially produce lithium for EV batteries.

In the motor zone was POSCO Daewoo’s a high-efficiency traction motor core for EVs made with POSCO’s Hyper NO, its highest-grade, non-oriented electrical steel. POSCO is already supplying it to major automakers.

The charging infrastructure zone showed POSCO ESM and POSCO Chemtech’s core materials of EV batteries, such as cathode and anode materials. In addition, POSCO ICT is the only company in Korea to provide a total-service electric vehicle charging infrastructure, including supply, installation and operation to membership management and supplementary services.

To close, POSCO pledged to become a “Total Solution Provider” for its partners in the auto industry bracing for the age of electric vehicles with its innovative technology, premium products and customized services.

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Contrary to popular belief, mass reduction does not automatically equal fuel savings, especially when it comes to urban driving. There are other factors that determine the fuel efficiency of a vehicle such as driving cycle, vehicle size and its powertrain. Until recently, there was a  lack of variety in engine types and powertrains, so even though automakers reduced the weight of car frames, they could not apply a complementary engine or powertrain to the lighter parts.

So, have automakers been lightweighting for nothing?

Of course not, in the past decade alone, engines and powertrains have also become extremely efficient through advancements in start-stop-systems and downsizing, and newer options including hybrids, electric batteries and range extenders that now allow automakers to capitalize on their lightweight materials.

Although there are several lightweight materials, below are 5 reasons why AHSS continues to be the lightweight material of choice for automakers:

1. Decision Makers Care About the Environment

Well, not everyone, but many countries around the world have started the process to phase out gasoline and diesel-fueled cars, including India and China, the two largest automotive markets in the world. Governments are taking serious action against climate change and it will reflect in their policies. Automakers are choosing to lightweight their vehicles for lower emission rates with AHSS, because not only is AHSS lightweight, there are no trade-offs with other vital features such as safety and cost-effectiveness.

2. Everyone’s Going Electric

Globally, automakers are investing in electric vehicles (EVs) in line with national and international environmental policies. However, EVs still have a ways to go before they become the norm. EVs will face the same safety requirements as regular cars, but with the added responsibility of protecting the battery and its flammable components during a crash.

In 2016 there were several car accidents involving the Tesla Model S, where leaked battery fluids caused fires. Automakers need to find a solution to make EVs as safe, and eventually, safer than traditional cars. As an innovative automotive material, AHSS was built for safety.

3. Safety is Always First

Safety is and should always be the number one priority for automakers, material providers and policymakers alike. Even with all the hype about autonomous driving and sensors, there is very little chance that policymakers will reverse the stringent safety regulations in place today. People want to feel safe, no matter what type of car they are getting into.  

2016 Smart Fortwo and the Mercedes S Class take part in a crash test (Source: Green Car Reports)

One possible material solution is Complex Phase (CP) steel, a type of POSCO GIGA STEEL for the vehicle’s side panels, bumper rails and door impact bars- the parts that determine the safety ratings of the vehicle. It has superior strength and shock-absorbing qualities, without the added weight of traditional high-strength materials, and that’s why carmakers such as GM Korea, Ssangyong Motors and Renault Samsung Motors all use POSCO GIGA STEEL.

4. Cost is Always Second

This goes for automakers as well as drivers on the consuming end. Drivers want lower costs without compromising safety and performance ratings, and desire fuel efficiency- a major reason why automakers are lightweighting.

Some automakers choose alternative materials such as aluminum and carbon fiber to meet lightweight requirements to find that not only are the materials more costly over steel, factories need an equipment overhaul to work with them. Moreover, there are additional costs related to training employees to work with new materials, whereas all auto manufacturers are familiar with welding and forming steel.  

Take a look at this infographic and see how AHSS stacks up against other lightweight materials in terms of cost and performance.  

5. It’s Not Over Till It’s Over

No two lightweight materials are the same when observed under the life-cycle approach, a comprehensive life cycle assessment of a material’s automotive carbon emissions from production to disposal. Often times, the process of manufacturing lightweight materials and improved powertrains result in more carbon emissions than they are saving.

The life cycle assessment can be used to determine the carbon output of a vehicle. (Source: World Auto Steel)

At the end of the day, steel has the lowest production-related emissions and can be recycled at the end of its lifecycle. Steel remains the most recycled material because it can be reapplied in different forms almost infinitely.

Automakers are increasingly incorporating lightweight materials to their new models. Although competition for the greatest market share of lightweight materials is fierce, AHSS is by far the leading material when it comes to lightweight solutions. According to McKinsey & Company’s Lightweight, Heavy Impact report, the percentage of high-strength materials used for cars will increase to 38 percent by 2030, compared to 15 percent in 2010. Steel continues to evolve according to the changing demands of the auto market, and for now, there is no other multi-solution material that can compete.

Cover photo courtesy of Hyundai.

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