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.

Auto Industry’s Challenge to Meet Consumer Demands

Mileage, design, and emissions. Which do you consider the most when purchasing a car? It is difficult to say that one is more important than the others, and fortunately, POSCO GIGA STEEL offers unique benefits for each one to meet the needs of today’s auto industry as it faces increasingly strict demands on safety and fuel efficiency.

More than ever, the industry is requiring that a vehicle goes longer distances with less fuel, which means the car must be lighter.  Also, technological advances have enabled cars with more power, requiring them to be safer. Consumers also want a car that represents their personality, demanding vehicles with more sophisticated and elegant designs.

Cars now need to drive smoothly, burn less fuel, and ensure safety, all while boasting an elegant design (Image courtesy of Mercedes-Benz AG).

While there are other conditions that need to be considered, it is paramount that cars meet the following three conditions in order to satisfy consumers: fuel efficiency, safety, and design. But these demands are becoming increasingly difficult to meet, and the only solution is to discover a technology that enables all of the above. For safety considerations, in the event of a collision, parts of the car also need to absorb the kinetic energy and protect the passengers inside.

In addition to having a battery and electric motor, the electric car is different from standard cars because the battery is a part of the frame itself.

6 Types of POSCO GIGA STEEL Tailored for Different Auto Parts

A car’s body frame requires different steel products for specific parts (Image courtesy of Renault)

POSCO GIGA STEEL is an advanced high-strength steel (AHSS) that can meet these various demands. Let’s take a look at the different types of POSCO GIGA STEEL products and how each one is being used in different parts of the car.

Complex Phase (CP) Steel

Complex Phase (CP) steel is often used to make reinforced auto parts that require high crashworthiness ratings, such as sill side panels, bumper rails, and door impact bars. It plays an extremely important role in the car frame as it is highly resistant to dents or bumps. In the past, the side panels of race cars were purposely made to be thicker in order to prevent dents and protect the driver inside and this naturally led to the vehicle becoming considerably heavier. However, CP steel minimizes these disadvantages. In the event of an impact, cars made with CP steel retain its original shape considerably better than other car frames due to its high strength and also has an exceptional ability to absorb all of the energy while still exhibiting an impressive thinness. It is often incorporated into the sill side panels and door impact bars to allow for a more spacious design.

Dual Phase (DP) Steel

Dual Phase (DP) steel can be easily welded and deformed and boasts a high level of total elongation (the rate at which the material is stretched without snapping). DP steel is commonly used in seat rails or other lower body reinforcements that run underneath the passenger seat. The tensile strength is at least 980MPa, but because it also exhibits impressive ductility, it can easily be used for random spare parts.

Transformation Induced Plasticity (TRIP) Steel

Transformation Induced Plasticity (TRIP) steel first made its way into the auto industry about six years ago. As the auto industry is beginning to value lightweight cars more and more, TRIP steel has received more attention. It is mainly used in the inner parts of the car body. This part of the car needs to absorb shock and impact and also be flexible enough to be fitted around the complex inner structure of the car. With TRIP steel’s outstanding combination of strength and ductility, it is one of the most commonly used high-strength automotive steels in the auto industry today.

Martensite Steel (MART)

Because Martensite steel is naturally high in strength, thinner sheets produced from roll forming (a metal forming process in which steel is continuously shaped or formed until it reaches a desired cross-section) still retain the same level of performance as conventional parts. Thinner parts also have the added benefit of reducing the weight.

Hot Press Forming (HPF) Steel

Hot Press Forming (HPF) steel is a different class of steel made with a unique steel production process. Typically, as steel becomes higher in strength, it is more difficult to mold into the desired shape through conventional processes. However, through the HPF process, the steel is heated to 950℃ before press forming. At high deformation temperatures, steel sheets are very soft so that difficult shapes can be obtained easily. During forming, the heated steel sheet cools down rapidly in the die block, so that the resulting pressed parts have a very high strength level. Due to its combination of high strength and formability, HPF steel is often used in the B-pillar of a car which requires intricately shaped parts as well as the A-pillar roof side rails which are prone to damage.

Post Heat Treatment (PHT) Steel

The chassis that supports the car frame needs to be extremely durable and resistant to impacts or shocks on the road as its main function is to improve the ride quality of the vehicle.
In order to increase the durability and torsional resistance, the material needs to be quenched and tempered. Before going through the heat treatment portion of the process (quenching), the material can be easily molded into spare parts due to its reduced strength. After being molded, it is heated up to 950°C and then rapidly cooled by water. This is why PHT is called “post-heat treatment steel”. Due to its ultra-high strength, it also has lightweighting benefits and is typically used in a vehicle’s chassis, stabilizer bars in a suspension system, and torsion beams.

These six types of POSCO GIGA STEEL each have their unique advantages in terms of processability & strength, production cost, and ease of application. Compared to conventional materials, thinner pieces can be used while still retaining the same level of performance and strength. Due to these incredible characteristics, POSCO GIGA STEEL is able to meet the increasingly stringent requirements of the auto industry for safety and efficiency.  

Image courtesy of Renault

Researchers in the auto industry are constantly looking for a stronger, more formable material. As the auto industry undergoes another paradigm shift, POSCO GIGA STEEL will continue to offer unique solutions that can satisfy both automakers and consumers.

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It combines several unique features:

• Strength & Safety: POSCO GIGA STEEL is more than three times stronger than automotive aluminum. Because of its high strength, POSCO GIGA STEEL also adheres to some of the most stringent international safety standards.

• Formability: Because the mixing ratio of manganese has been precisely controlled, POSCO GIGA STEEL has highly formable properties that allow it to be made into complex auto parts without any special processing.

• Lightweighting: Because POSCO GIGA STEEL boasts high strength, it is possible to use less of it. This ultimately makes it lighter than car frames made of general steel or aluminum.

• Affordability: POSCO GIGA STEEL is a cost-effective solution for automakers, especially when compared to alternative materials, which in turn helps lower prices for consumers.

• Sustainability: When looking at the entire lifecycle of a vehicle made with steel, POSCO GIGA STEEL emits 10% lower CO² emissions compared to aluminum.

Take a look at the infographic below and discover the benefits that POSCO GIGA STEEL can bring to both automakers and consumers today.

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Establishing the Foundation Solution Marketing through POSCO Tech Day

The overall result of ‘POSCO Tech Day’ was marvelous: 1,352 people attended the event held at Gwangchi Toyota on January 30th and 1,050 people attended the Gwangchi Honda event. This event has an exceptional meaning to both Gwangchi Toyota and Gwangchi Honda. Because the companies had never previously held an in-house event with an exclusive invitation to a single supplier.

Along with the introduction of POSCO, EVI (Early Vendor Involvement) activities and case examples of solution marketing were presented at the event. Localization strategies through operating Guangdong Pohang Automotive Steel, TSC (Technical Service Center) and POSCO-CFPC were also presented. Moreover, other information such as world premium products, unique steel technologies, and new steel material demand development activities, which are executing with auto parts companies, were introduced.

Above all, ‘POSCO Tech Day’ drew client’s interest and emotions through content that emphasizes automotive structures. Clients who experienced POSCO’s solution marketing at the event expressed their eager interests by sounding out cooperative business possibilities with auto parts companies.

Targeting engineers and purchasing department of each company, the event’s technical seminar focused on Advanced High Strength Steels (AHSS), utilization techniques, performance evaluation, and stainless auto parts products.

Perspectives for POSCO in Guangdong, China
This event is expected to strengthen the future technical partnership in Guangdong, China by raising the potential for practical solution demand identification and joint technical project research. Moreover, it is estimated that the event has helped to enhance the global automotive client networks and increase the actual promotion effects. The greatest outcome of the event is the fact that the foundation for POSCO’s solution marketing is constructed in China, the country that is rapidly developing as the world’s largest automobile market with considerable inbound investment from global automakers.

POSCO will build on this event to actively pursue differentiated client-oriented care, new steel product development, and enhanced commercial support. In the second half of this year, POSCO will hold a technical seminar focusing on local TSC for other global automakers and respond to client’s needs for car body weight reduction and advanced product design capabilities.

Meanwhile, POSCO was the first steel company to be invited to a technical exhibition of PROTON, the only local automotive company in Southeast Asia, in September 2014. POSCO also showed that POSCO is leading the field of car body weight reduction through developing new steel grades and participating in the development project of Renault’s EOLAB concept car which was unveiled at 2014 Paris Motor Show.

If you are interested in more information, scroll down and check out global automakers’ displayed items at ‘POSCO Tech Day’!

PBC-EV (POSCO Body Concept for Electric Vehicle) at EVI Activity Section
By applying the cutting edge technology such as PosM Steel and hot press forming, PBC-EV is lighter than the previous car bodies.

(From left) Rear Lower Arm, First Generation Styled Wheel, Front Lower Arm, Fuel Tank

Electricity Motor Cores (manufactured with electrical steel) at Power Train Section
(Left)Bonded Core Stack – EM Free
(Center)Core Stack – Embo Type
(Right)EV Traction Motor Core (Electric Vehicle Motor Core)

Front Sub-frame Upper at Chassis Section

Introducing POSCO’s Global EVI Forum

EVI (Early Vendor Involvement) is an activity, initiated by finished vehicle companies, brings the key auto parts companies to participate in new model development projects. The POSCO EVI Forum, which started as a domestic auto market target event, has been developing into a global event where various industry fields and global client companies participate in; also expanding the contact points with POSCO’s clients in the meantime. Currently, the event is positioning as client-oriented marketing festival to strengthen business partnerships with customers, while facilitating interaction and exchange with potential global clients.

Presentations and Discussions of Six Major Industrial Programs

During the general session which also includes the opening ceremony on the 28^th, Remi Bastian, Renault’s head of research, advanced studies and materials, Sungho Park, POSCO’s Director of Research Center and Raghavan Ayer, SK innovation’s Science Advisor and Senior VP made presentations on industrial topics. Except for the opening ceremony and the general session, the discussions were arranged into six major industrial programs, including automobile, energy, shipbuilding, electricity, electronic, construction, stainless, and wire rod.

Each session’s presentation and discussion on ‘Steel Solution for Eco-friendly Vehicle of Now and Future’, and ‘Energy·Shipbuilding Solution for Client’s Best Value’ intensified the concentration and communication among clients and participants at the event. There were hosted discussions about industrial technology trends, followed by topic-based presentations. Noteworthy examples included a presentation on technology development designed to lighten the weight of automobiles that was undertaken by Volkswagen in Germany; the development of Hadfield steel LNG tanks from Daewoo Shipbuilding & Marine Engineering and the usage of wire rods in the marine industry by KISWIRE.

Also, the forum provided a special location to global clients of each session for technology consultation and purchase agreement, presentation and discussions. In fact, POSCO successfully established positive relationships with global clients through the technology consultation and sales agreement were proceeded for two days from the 27^th to the 28^th.

Focus on Renault’s ‘EOLAB’ of POSCO Chassis

As a rapid adaptation to the trend of European auto industry, Renault has recently introduced its hybrid concept car ‘EOLAB’ (a compound of the Greek god of wind ‘Aeolus’ and the English word ‘laboratory’) which contains POSCO’s steel products. Therefore, the unique technologies of POSCO were praised, including its lightweight· high strength products, which were used in the ‘EOLAB’ prototype. Other noteworthy additions included POSCO’s magnesium plating and PosM Steel, which received much attention from global client companies.

As a result, POSCO was able to sign various technology agreements and sales contracts during the automobile session which is one of the six industrial programs at the forum. Also, POSCO pursued a long-term cooperation with domestic and global companies of the finished vehicle and key auto parts at the same session of the forum. Moreover, POSCO agreed on technology cooperation and joint marketing activities with key domestic and global client companies for shipbuilding, construction, electronic appliance and wire rod.

Creating Successful Partnership through POSCO’s Solution Marketing

Also, this year’s forum has acquired a favorable comment by creating a special counter for POSCO’s solution business introduction and registration for the clients’ request on solution development. Even after the 2014 Global EVI Forum, POSCO promises to continue to seek for practical approaches to the customer value creation. Also, POSCO will further reinforce its growth foundation with clients by amplifying the solution marketing not only to domestic clients but also to distinguished global client companies.

In the next episode of our global blog’s Global EVI Forum series, we will introduce the in-depth explanations of each forum session and interviews with our client companies. So, please stay tuned with us!