As descendants of “handy man (Homo habilis)”, we have created civilization by adjusting to and, at times, challenging the rough and ever-changing environment. Megacities with cars moving through a cluster of high-rise buildings, trains crossing long bridges, and airplanes flying, leaving white streak in the sky, show typical features of modern civilization. The use and advancement of tools led to the increase in industrial productivity, and, coincided with the physical expansion of the society, brought about the development of human civilization. Materials, which have played a fundamental role in increasing the efficiency of tools, are becoming a standard for determining the different stages of development of a civilization.

Tools made from materials that are easily found in nature, such as wood, straw, and stones can be commonly found. Objects and tools made from metal are also or even more commonly found. The use of metal in making tools began later than other materials as it is rather complex and requires elaborate use of fire to make metal from raw materials.

However, metals have become the most important material in today’s industrial society due to their strength and formability. Among various metals, steel has played a leading role due to the availability of the natural resources and is highly formable after relatively simple adjustments. As such, the production and consumption of steel can be an indicator of the level of development of a country.

“Dislocation” Sets a New Course in Metallurgy

Metals are typically solids at room temperature. Think of toys that consist of small individual pieces to be assembled to form a single larger object. Many solids are formed by regular arrangements of symmetrical structures (e.g. a cube) made of atoms in an infinitely repeating pattern, filling a three dimensional space. This is known as crystal structure.

The level of force between the atoms in a metallic crystal is known to be weaker than the force in other solid forms. Also, a crystal structure typically contains crystallographic defects that do not conform to the regular arrangement. Among the defects, “dislocation” greatly influences the mechanical properties of the crystal structure.

In a dislocation, empty spaces between atoms create a long, straight line. Tapping, bending, or stretching the metal is a process in which the dislocation within the metal is created and rearranged. Because the level of interaction between the metallic solid atoms is low, pre-existing chemical bonds can be easily broken to form new ones. In other words, it is possible to alter the arrangement of the dislocation and create a new form by exerting force. On the other hand, strongly-bonded crystal structures of other solids, such as salt, are difficult to alter their shapes as they are easily broken by exterior force.

Effective Control of “Dislocation” is a Metallurgist’s Dream

Developing strong, unbreakable, and ductile materials is a long standing dream of metallurgists. The key question to consider here is how to control the movement of the dislocation within a metal.

Metallic materials are produced by mixing two or more atoms to form an alloy. Their properties depend on the ratio of atoms and the manufacturing process.

Giga Steel, successfully commercialized by POSCO, is a high-strength steel designed and developed to create twinning, structures in which the left and right sides are symmetrical each other like a mirror image or to alter the crystal structure during plastic deformation by controlling dislocation. It can be considered as state-of-art metallic materials.

Going Beyond the Norm

Metallic materials have many stories to tell and metallurgists are becoming more elaborate in telling these stories. Here, we will highlight two recent accomplishments in metallurgical research, the first being high-entropy alloys.

Traditionally, metallic materials were developed as alloys made by combining two or three minor elements with major one depending on the required properties. A high-entropy alloy is formed by combining five or more elements in identical or similar ratio without a major element. This method enables alloys to be produced in almost-infinite varieties, and alloys with excellent cryogenic properties, corrosion-resistant alloys, have already been studied and presented.

Study results reveal that high-quality mechanical properties of the high-entropy alloy are closely related to twinning. This reaches beyond the common knowledge of metallurgy as it was previously assumed that these alloys existed beyond the scope of twinning.

The International Cooperation Research Team of Graduate Institute of Ferrous Technology, POSTECH in Korea and KTH – Royal Institute of Technology in Sweden, developed a general theory of the atomisitic level and conducted quantum mechanics calculations. As a result, it was revealed that the high-entropy alloy is a different class of material in comparison to the conventional alloys and that twinning occurs more effectively, thus attaining high mechanical properties.

Ultra-Light and High Strength

The second accomplishment to highlight is the ultra-light and high-strength steel developed at Graduate Institute of Ferrous Technology, POSTECH. An alloy was designed to combine into steel containing high ratio contents of manganese and aluminum with a less amount of nickel, then the processing was controlled to produce small-sized secondary crystals.

Chemically stable secondary crystals were known to degrade the properties of metallic materials, and were thus avoided. On the contrary, the mechanical properties of the newly proposed alloy have been found to be superior to the conventional steel materials, including even titanium-alloys developed for aircraft materials. This implies that we should open a new chapter in the field of metallic materials with a new generation of high-alloy steel such as POSCO’s Giga Steel, high-entropy alloy, and ultra-light high-strength steel.

In Pursuit of a Safe and Sustainable Future

As descendants of “wise man (Homo sapiens)”, we should consider the future of our planet and civilization and demonstrate wisdom. The scientific knowledge that has led us thus far will guide us through the challenges faced by the humanity.

The role of metallurgists is also important. They would have to search deeply within the fundamentals, applications, and domains granted by Mother Nature to discover and apply versatile materials and contribute to creating a safe, efficient, and sustainable future.

The budget for the entire event was estimated to be around USD 10 to 13 billion to get PyeongChang in prime shape to host more than 6000 athletes and officials from all over the world. As a result, the winter games will take place in 13 different venues, 6 of which have been newly built and the remaining 7 were renovated specifically for use during these games.

The Olympic flame lands in PyeongChang during the flame lighting ceremony. (Source: Sputnik News)

As the biggest steelmaker in Korea, POSCO played a crucial part in building the International Broadcast Center (IBC), Media Residence Hotel and the Kwandong Hockey Center with its World Premium Products and innovative construction solutions.

SEE ALSO: POSCO Steel Shines at the 2018 PyeongChang Winter Olympics

International Broadcast Center

This year’s Winter Olympics will set a new record as the first Olympics to be broadcast live in all U.S. time zones, and all of this will be coordinated through the IBC. POSCO custom-made H-beams for the center’s pillars and columns using Pos-H, a type of steel produced by precisely cutting and welding POSCO’s hot-rolled steel plates and thick plates together.

The HSA5-based Pos-H is seismic wave resistant and can be customized to fit specific height and thickness requirements for different parts of a building. Plus, compared to existing hot-rolled steel which only comes in a standard size, manufacturers have the added benefit of reducing the amount of steel used, thus saving costs.

For the first time ever, all time zones in the U.S. can watch live coverage of the Olympics. (Source: Heerim)

POSCO also applied GI-Ace steel and fire-resistant cladding to the IBC’s columns to not only increase fire resistance but reduce construction time. POSCO’s dry fire-resistant cladding is different from traditional methods that require numerous layers of fire-resistant paint to be applied, requiring additional manpower and hours to complete. Dry-cladding can be wrapped around the surface of the columns in a one-time process.

Finally, the 5-story IBC is now capable of supporting a much larger load thanks to a new composite beam with concrete integrated into POSCO’s SM490 steel. Overall, POSCO supplied 8,218 tons of steel for the IBC.

Media Residence Hotel

The Media Residence Hotel is another important facility POSCO’s materials and construction solutions played a vital role in. POSCO wrapped the exterior walls of the 300-room, 4-story building with PosMAC, a magnesium alloy coating, that is 10 times more corrosion resistant than standard galvanized steel.

The interior walls are also lined with steel. Instead of wallpaper, the Media Residence Hotel is lined with a special type of printed steel that feels like fabric to the touch. POSCO also applied PosMAC to the modular bathroom floors instead of traditional tiles. PosMac is 5 times more corrosion-resistant than zinc plating, and has an aesthetically-pleasing finish. POSCO’s stainless steel, PossSD, made up other parts of the bathroom as it is also highly corrosion-resistant and workable. In addition, each entrance was made with POSCO’s high-strength and corrosion-resistant 329LD duplex stainless steel with surface treatment and color processing.

Media Residence Hotel was constructed off-site, then put together at the venue. (Source: The Korea Herald)

What’s noteworthy about this construction project is that 100 percent of the building was constructed off-site via modular construction. Compared to the time it would take to build a traditional concrete building of the same scope, the construction period for the Media Residence Hotel was 18 months shorter. Since each room is a relocatable building unit, it will be moved to a different venue and recycled as another hotel or dormitory. All in all, POSCO supplied 1,405 tons of steel for the entire construction project.

Kwandong Hockey Center

Kwandong Hockey Center will be home to some of the most exciting action of the winter games, and the facility was built on the “ice wave” concept to reflect the dynamics of ice hockey, waves of the nearby East Sea and the region’s strong winds.

Again, POSCO’s duplex stainless steel 329LD was used to cover the stadium’s exterior to protect against rapid corrosion that is prevalent in coastal areas. Aside from protection against corrosion, the stainless steel is extremely high in strength, allowing the builders to reduce the thickness of the steel plates by 25 percent compared to standard types of stainless steel.

POSCO’s duplex stainless steel keeps the Kwandong Hockey Center strong and corrosion-free. (Source: Curbed)

POSCO also aided the construction process by providing additional support such as internal wind pressure structural analysis, surface treatment and a panel processability evaluation to maximize the benefits of POSCO’s products.

With these new and upgraded facilities completed, PyeongChang is now equipped and ready to host the 23rd Winter Olympics. The only thing left to do now is to witness history as the best athletes from all over the world compete for gold. Best of luck to all the Olympic and Paralympic athletes!  

Cover photo courtesy of Snow Best.

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.

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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The Korean National Para Ice Hockey Team playing against the U.S. national team in 2014 (Source: Aljazeera)

Para ice hockey, previously called ice sledge hockey, may not be common to everyone, but many consider it the highlight of para-athletic events. A team is composed of athletes who have a physical impairment in the lower part of their body, so instead of wearing skates, they glide through the rink on ice sledges (also known as sleds).

Watch any para ice hockey match, and it will be surprising to see that there is as much, if not more physical contact than regular ice hockey. Although these athletes may be limited in their everyday movement, on ice, they appear to be flying on their sledges.

The thrill and intensity of the sport are just some of the reasons why steel-company POSCO continually supports the Korean national team and para-athletics in general. It is also why POSCO joined the mission to create specially-made sledges for the Korean National Para Ice Hockey Team.

Ice Sledges Make or Break the Match

Due to the nature of the sport, the sledges have to withstand various forms of physical contact such as body checking. They also have to move in complete unison with the players, almost like an additional limb, because it determines the player’s’ steering and control of direction.

So, the sledges have a direct impact on performance.

Some members of the Korean national team have been playing for over 18 years, and they know better than anyone the importance of their sledges in relationship to performance and results. Ideally, a sledge has to be light yet strong, able to absorb shock from external contact and fit the athlete’s body perfectly.

A Korean National Para Ice Hockey Team player fights for the puck during a game against Japan.

All of the sledges the Korean ice hockey team used were previously imported from Canada. The sledges were heavier and often could not withstand harsh contact. On average, 5 to 7 sledges were damaged during a game and required repair work.

That’s why Massive Blade, a company that specializes in ice sports equipment, decided to make the sledges domestically in Korea. When POSCO heard that Massive Blade was looking for a light and strong material to build the sledges out of, researchers jumped on board the mission to produce these new and improved sledges.

The First Domestic Sledge, Built with POSCO’s Technology

This first-of-its-kind sledge was made with POSCO’s new high-strength magnesium alloy, high-manganese anti-vibration steel and stainless steel. Meaning, they replaced the heavy aluminum alloys that made up the previous sledges with POSCO’s advanced materials.

Magnesium

Magnesium has a high specific strength (also known as the strength-to-weight ratio) and is about two-thirds lighter than aluminum. The downside is that it is challenging to mold, so it is not widely used despite its phenomenal lightweight and specific strength qualities. This is where POSCO’s Research Institute of Industrial Science & Technology (RIST) stepped in to provide a solution

RIST has been researching magnesium and its production technology for application in mountain bike frames and car frames for 3 years. As a result, RIST also owns the necessary equipment and machinery for processing and producing magnesium parts. In order to develop their technology for processing magnesium, RIST researcher Lee Mok-Young said they had to first identify the characteristics of the material, maintain the proper heat treatment temperature and optimize the accompanying tools for molding magnesium. The molding tool is a new, innovative technology that ultimately decides whether magnesium can be shaped into the necessary parts.

RIST researchers came up with a processing technology to increase the moldability of magnesium

When the processing technology is applied to magnesium, it results in a material that is approximately twice as moldable as regular magnesium. As a result, magnesium was able to be applied to sledges for the first time ever.

High-Manganese Anti-Vibration Steel

High-manganese anti-vibration steel is another material that helped enhance the sledges. They applied it to the parts of the sledge with the most exposure to contact such as the front bar and bucket brackets to prevent injuries as well as to minimize structural deformities. High-manganese anti-vibration steel is widely used in buildings for shock absorption, and according to Kim Sung-Gyu, director of the Gwangyang Steel Commercialization Promotion Team, the anti-vibration properties of the steel make it possible to contain vibrations from external force within the metal. This means less shock is transferred to the players, minimizing the risk of injury.

A technician applies high-manganese anti-vibration steel to the front bar

Stainless Steel

Finally, POSCO’s stainless steel was applied to the sledge blades. There are two blades at the bottom of every sledge, and each blade is 3mm thick. It is important to use high-strength steel so that the thin blades can stay sharp and carry the weight of the sledge and player throughout the whole game. Plus, the blades have to hold the frame 8.5cm to 9.5cm above the ice so that the puck can pass through freely under the sledge. The length of the blade also cannot exceed one-third of the total length of the sledge.

Stainless steel blades are sharpened and reattached

That’s a lot of work for just two blades, and that’s why POSCO’s stainless steel was applied. Besides the fact that it has optimal high-strength, hardness and ductility qualities, stainless steel is corrosion resistant, an important factor for blades constantly exposed to water and ice.

Korea’s National Para Ice Hockey Team Gets Wings

Aside from choosing the right materials, POSCO’s RIST researchers spent the most time trying to understand the difficulties and discomfort the para-athletes face on the sledges. It is true the sledges have to be light and strong, but there are further limitations to gauge precise movement and direction during an intense and dynamic game.

That’s why the researchers scrapped the project in its final stages multiple times to start over. During the process, they made numerous models and constantly talked with the players, coaches and the director. Not only that, the RIST researchers also consulted POSCO’s engineers about technical issues related to the materials. The finished product is really the accumulation of intensive research and running back and forth between the rink, the RIST research lab and POSCO offices.

National team members are adjusting to the new, upgraded sledges

The result of their collaboration is a sledge that is 34 percent lighter and capable of absorbing greater shock than the previous sledges.

The players are already adjusting to their new equipment and it won’t be long until they can test them out in an actual match. POSCO will continue to support para-athletes and the Korean National Para Ice Hockey Team so they can focus on their intensive training without worrying about sledge malfunctions and injuries.

TO (a safe) VICTORY!

Cover photo courtesy of Team USA Hockey.

Compared to the world’s very first cars, today’s cars are faster, stronger, safer and have more sophisticated designs. As alternative materials like aluminum are increasingly being used for car parts that were originally made of steel, some even refer to this trend as a “material war.”

“Material War” in the Auto Industry

Recently, various substitutes for steel have entered the picture and are being applied in commercial vehicles. The most commonly used materials are aluminum and CFRP (Carbon Fiber Reinforced Plastic).

Beginning in the 1930’s, aluminum was primarily used as a lightweighting material for race cars and the outer panel of a vehicle. On the day of the Eifel race, the Mercedes-Benz weighed over the maximum limit and in an attempt to resolve this, the white paint was stripped from the frame, leaving the car’s aluminum frame completely exposed. This is how the Benz got its famous nickname, the “Silver Arrows.”

Pictured is the Mercedes Benz “Silver Arrows” racecar with its paint completely stripped off to reduce the weight. (Source: Daimler AG)

Safety regulations were less strict then than they are today. If there was an accident, the outcome would most likely be a severe injury or even death. With the goal of increased protection, researchers began to use tubular frames made of chromium molybdenum steel in order to reinforce the rigidity of the vehicle.

As the 1970’s rolled around, CFRP, a material that was already being applied in the aerospace industry, made an appearance in Formula 1 and automotive researchers quickly began discovering its potential and value. Soon enough, CFRP was considered an ideal material for race cars.

The Audi A2 and A8 made with aluminum car frames during the early 2000’s (Source: Audi AG)

The rapid implementation of new substitute materials in the motorsports industry set a precedent for the auto industry as well. In the early 2000s, Audi shocked the industry by presenting the A2 and A8, two vehicles with car frames that were made completely out of aluminum. In 2015, BMW created a large-sized sedan made of CFRP, which was only used in a limited number of cars. This stunned consumers and the industry yet again. As advances were made with aluminum and CFRP, it seemed that steel would inevitably lose its place in the automotive material industry.

However, those who believed that the age of steel was over forgot one thing: steel is constantly evolving. While it is true that aluminum and CFRP could replace steel and that they are lighter, the disadvantages that come with these materials confirm that steel is a much more efficient material.

Aluminum

Aluminum, for example, is lighter than steel, but because it has less strength, thicker pieces need to be used. In order to achieve the same level of strength as steel, it needs to be mixed with other materials. Also, aluminum has a low melting point and easily leads to the formation of the oxide film, a factor that makes it difficult to weld. The high thermal conductivity makes the heat that is produced at the time of welding spread, making the material more brittle.

These disadvantages mean aluminum has to be welded in other ways such as riveting, a method of mechanical joining using thick mushroom-shaped nails or adhesive. If the aluminum is not tightly joined during the riveting process, oxide films form in between the cracks resulting in fatigue failure. If a tackifier was used in the process, an impact or collision could easily rupture the adhesive lining. Addressing these problems, while also ensuring that the frame is durable and light, has proved to be a much more expensive process than manufacturing a traditional steel car frame.

As such, numerous factors including durability, safety, and efficiency must be considered when choosing a material to be applied to a car.

From the 1930s to the ‘70s, it was possible to use aluminum in race cars because the vehicles were only used for one or two races. The aluminum pieces were hammered into shape by hand or joined together by rivets, but mass production of aluminum car frames was a very difficult operation. To this day, aluminum is still a difficult material to work with due to its high cost and the complicated technology involved in the production process.

CFRP

CFRP, which is known to be lighter and stronger than steel, also has several issues. Although a method for mass production has recently been established, it requires a much longer production time (the time allowed for one product to be produced) for a car body or shell, meaning that it also yields higher labor costs.

The McLaren MP4/1 was the first car frame to be made from CFRP.

Recently, Boeing and BMW began to research ways to recycle CFRP, but unlike steel or aluminum, it is fundamentally impossible to melt CFRP and give it a “new life”. Another reason why it is not an eco-friendly material is that various chemical products are used in the manufacturing process.

Also, 80% of carbon fiber production, one of the core materials in CFRP, is used by the aviation industry. Because the demand is much higher than the supply, it is much more expensive than steel and has yet to fully make its way into the automotive industry.

Because these shortcomings have not been addressed, researchers have started to turn their eyes back to steel. Even Audi, which once considered its aluminum car frames a major strength, has adopted steel to create the car frame for their newest sedan. Other major automakers still continue to look to steel as the main material as well.

The Shift Back to Steel

The reason for the shift back to steel is because it not only addresses certain disadvantages of alternative materials but also because it is a more affordable choice. The launch of POSCO GIGA STEEL and PosM, in particular, introduced a whole new level of steel.

Audi has turned away from a fully aluminum car frame and has begun incorporating high-tensile steel plates, as indicated by the purple portions of the car frame.

[clickToTweet tweet=”PosM is POSCO’s unique brand of steel that goes beyond the limits of traditional steel plates and exhibits a new level of performance.” quote=”PosM is POSCO’s unique brand of steel that goes beyond the limits of traditional steel plates and exhibits a new level of performance.” theme=”style6″]

PosM includes three different series of steel. The “E Series” focuses on elongation, the “Y Series” focuses on the yield strength and the “B Series” balances the benefits of the two.

The highlighted parts represent the parts that have been applied to the “E Series” of PosM

PosM “E Series”

The “E Series” was once thought to be only theoretically possible and has long been known as a dream material amongst the world’s leading steel companies. This is because it can meet two demanding conditions at once: strength and formability.

Not only does it have 2-9 times more processability compared to existing materials, it also has an excellent ability to absorb impact, which can make a car safer when used in those engine room parts that absorb and disperse impact.

Many steel companies attempted to produce this material but were not able to complete it due to difficulties in production. However, in 2008, POSCO successfully developed this material for the first time and made it available for purchase.

The highlighted parts represent the parts that have applied the “Y Series” of PosM.

PosM “Y Series”

The “Y series” is used for the parts of a car that protect the passengers, especially because of the yield strength, which represents the strength of a material until it becomes deformed, is quite high. This includes, for example, filler parts that prevent the passenger compartment from becoming damaged in the event of a collision.

PosM “B Series”

The “B series” has both the benefits of the “E series” and “Y series”. It is one of the best materials that can be formed by cold forming, which is a simpler process than what is used to make Hot Press Forming (HPF) steel. Because it is easy to process, it can be manufactured into complex shapes and yield a much lower processing cost.

Until now, there has never been a steel that could exhibit both high strength and durability like PosM has. PosM, first developed by POSCO in 2016, is an indispensable material for automobiles.

Through PosM, which exhibits next-level performance compared to existing advanced high-strength steel solutions, steel is once again being considered as an essential material in automobiles. Also, POSCO GIGA STEEL is rapidly advancing to meet the needs of today’s evolving industry, leading the advanced strength steel market.

POSCO GIGA STEEL, with outstanding processability, affordability and a tensile strength that is over three times that of aluminum with the same thickness, will continue to be a very important material in electric vehicles (EVs) which define the present and future of the automotive industry. It will help overcome the limits of batteries used in EVs and allow the vehicle to travel longer distances with its lightweight qualities and make the car body safer by satisfying the most stringent of safety standards.

In addition, the advantage of being more economical, cleaner and easier to recycle than other materials is necessary for an age where consumers value eco-friendly solutions. As long as cars exist, steel will always be one of the most important materials. Various manufacturers are already turning their attention to hybrid car frames that utilize a combination of aluminum, magnesium and carbon composites, with steel as the main focus.  As advanced high-strength steel continues to make improvements it has the potential to replace the need for these other materials altogether.

Automobile development continues to move forward with steel, and at the crux of this progress is POSCO GIGA STEEL.

Read part one on how POSCO GIGA STEEL goes beyond the limits of traditional lightweight materials and part two on how POSCO GIGA STEEL opens the door to the future of the auto industry.

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POSCO’s innovations in steel technology have long supplied material solutions for the automotive industry. Last year, POSCO sold approximately 9 million tons of automotive steel sheets, accounting for 10% of the global automotive steel sheet market. In 2017, POSCO’s focus on providing customers with the most advanced, high-quality steel continues with POSCO GIGA STEEL.

POSCO GIGA STEEL, the Beginning of a New Era

POSCO GIGA STEEL represents the apex of steel technology as it is lightweight, strong, and highly formable – exactly what automakers are looking for. Innovations in POSCO’s manufacturing processes reduce both its production emissions and price, making it a more sustainable and affordable option for car makers compared to other lightweight materials. See how POSCO GIGA STEEL is opening a new era for automotive steel in the video below.

POSCO GIGA STEEL Provides Strength & Safety

Automotive steel is categorized according to its tensile strength. POSCO GIGA STEELS fall into the highest category, which includes steels with a tensile strength rated at more than 1 GPa (Gigapascal), meaning it can withstand more than 100 kilograms-force per square millimeter. In the past, steels with tensile strength ratings this high have been problematic for automakers as they had low ductility and elongation properties.

What makes POSCO GIGA STEEL the ideal material for automakers is its ability to both bend and withstand an immense amount of weight and pressure. POSCO’s ultra high strength giga steel has up to three times more formability than other types of comparable steel on the market, making it ideal for manufacturers.

A car’s safety can also be enhanced significantly when POSCO GIGA STEEL is applied to a vehicle’s BIW (body in white) or front and back bumpers. POSCO GIGA STEEL is not only strong but has exceptional shock absorption during impact.

The strength and safety of POSCO GIGA STEEL have been tested and proven to meet the industry’s strictest safety standards. The POSCO Body Concept-Electric Vehicle (PBC-EV) is a lightweight and safe car body for electric vehicles made with POSCO GIGA STEEL. In safety tests, it received “five stars” from the Europe New Car Assessment Program and a “good” rating from the Insurance Institute for Highway Safety (IIHS) – the highest ratings one can receive from both organizations.

POSCO’s PBC-EV made with POSCO GIGA STEEL is both safe and lightweight.

POSCO GIGA STEEL Helps Deliver Lightweight & Sustainable Cars

Strict regulations on fuel efficiency and carbon emissions continue to push automakers to look for lighter materials to reduce the overall weight of vehicles. However, because stricter safety regulations typically require using heavier body parts, automakers are looking for both strong and light materials to build their cars. Lightweight solutions can be found in some alternative materials, such as aluminum and carbon fiber composites, but there are some drawbacks. For example, although POSCO GIGA STEEL is heavier than aluminum (when measuring equal parts area and thickness), it is more than three times stronger. Therefore, less of it is needed to manufacture products that are as light or lighter than those made with aluminum.

Car bodies manufactured with POSCO GIGA STEEL and other advanced high strength steels could see a 26% reduction in total weight when compared to cars of the same size with internal combustion engines. Considering that the average body weight of medium-sized cars in the early 2000’s was 280-300 kg, this is a remarkable achievement for automakers today.

Also, based on its life cycle assessment measuring carbon dioxide emissions from production to recycling, POSCO GIGA STEEL performs remarkably well as an eco-friendly material. According to the World Steel Association, steel emits 2.0 to 2.5 kg of carbon emissions when producing 1 kg of material while aluminum emits 11 to 12.6 kg when producing the same amount. Even after production, cumulative greenhouse gas emissions of vehicles made with steel is 10% lower when looking at the full life cycle.

POSCO GIGA STEEL Offers an Affordable Option

In automotive lightweighting, a reverse correlation often exists between price and weight. Lighter materials are typically more expensive and heavier materials usually have a lower price. POSCO GIGA STEEL helps bridge this gap by producing automotive steel that is both lightweight and cost-effective.  

Body parts made of POSCO GIGA STEEL can see significant cost savings. Alternative materials like aluminum can cost anywhere from 2.1 to 3.5 times more than POSCO GIGA STEEL. Additionally, current market prices of alternative materials are not expected to decrease over the next ten years.

Facing increasingly strict regulations, POSCO GIGA STEEL offers an ideal choice for automakers to build stronger, lighter, and more sustainable cars. According to POSCO Research Institute (POSRI), advanced high-strength steels (AHSS) like POSCO GIGA STEEL should see increased demand, accounting for 69% of total steel plates by 2023.

Throughout April & May, The Steel Wire will explore how POSCO is leading the automotive steel market with its innovative steel products like POSCO GIGA STEEL. Don’t miss any of the exciting stories from The Steel Wire – subscribe via email today. 

Volkswagen brought back its iconic Microbus in the form of a new electric, self-driving ID Buzz concept car. (Engadget)

The headlines from the Consumer Electronic Show (CES) were all about self-driving, electric, and connected cars. As these topics continued to be highlighted at NAIAS (see the new Volkswagen ID Buzz pictured above), there was also a focus on the importance of structural design.

Innovations in high-strength steel have allowed car makers to reduce the weight of vehicles without compromising safety. From large sedans to electric vehicles, advances in steel were spotted all throughout this year’s NAIAS with BMW’s new 5 Series and Ford’s new 2018 F-150 both showing off their lightweight aluminum and high-strength steel compounds that helped shed more than 100 kg from the BMW model.

The push to make vehicles lighter raises safety concerns. Lighter cars require lighter steel, and to make lighter steel there are typically other compromises that have to be made. POSCO, however, with its advanced high-strength automotive steel, has found the solution for automakers to make cars that are both safe and lightweight.

The new BMW 5 Series (left) and Ford F150 (right) made their debut at the North American International Auto Show. Both models used advanced high-strength steel to reduce weight and maintain safety. (NAIAS Image Archive)

POSCO’s Lightweight Auto Solutions Increase Safety

In 2016, POSCO became the first steelmaker to participate at NAIAS, displaying its advanced high-strength steel for automobiles, including its the PosM Steel and hot press forming steel (HPF). PosM Steel is five times stronger than other types of steel making it great for impact absorption and increased safety.

Providing a rapid solution upgrade for strengthened crash requirements, the safety of POSCO’s advanced materials has been certified by the Insurance Institute for Highway Safety (IIHS). In addition, the strength and crashworthiness of POSCO’s advanced steel solution received a score of 5 stars from USNCAP and ‘good’ safety ratings on the IIHS Moderate Overlap Front and Small Overlap Front tests. By reducing possible safety concerns with high strength body solutions, POSCO is able to contribute to the advancement of global auto manufacturers.

With steel being more important than ever in the auto industry, POSCO’s commitment to improving the strength and safety in its automotive steel has helped it maintain its position as a global industry leader. As Gregory Warden of GM said, “there is a whole new generation of steel coming” – and POSCO is helping to lead the way by creating new solutions that guarantee safety and fit the unique needs of its partners.

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When Tesla unveiled the Model 3, its low-priced EV, to promote sales, about 370,000 cars were pre-ordered globally in a single month. This was about 30,000 more than the number of Toyota Lexus models sold in the US last year.

As a result, Tesla decided to increase the vehicle production capacity to 500,000 until 2018 to keep up with the high demand of the market. This increase in vehicle production capacity is eight times more than the current vehicle production capacity, which is around 62,000 per year.

Automotive companies around the world are now rushing to getting into the game, marking the blossoming of the development of new electric vehicles. Market analysts anticipate that the EV will dominate the automotive market as quickly as smartphones transformed the mobile phone market.

Global Environmental Efforts Transform the Automotive Industry

As the main cause of global warming, cars using fossil fuels will no doubt cease to exist in the future. As a result, the world is experiencing a market shift toward electric vehicles faster than originally anticipated.

For example, EVs made up more than 19 percent of vehicles in Norway, a representative oil-producing country, by the end of 2015. Norway is also taking a legal step to ban the sales of cars that use fossil fuels starting in 2025. Other European countries including the Netherlands seem to be following this course as well. Clearly, the EV is no longer just a trend.

In addition, China—the world’s biggest automotive market—is providing subsidies (as much as $16,000 per car) to proliferate the use of EVs and mandating that these cars make up at least 50 percent of vehicle purchases by public institutions.

India, too, is changing their traffic policies regarding EVs to help reduce the country’s severe air pollution. India’s Secretary of Transportation said that the nation is establishing a strategy to ensure that all cars in India are electric by 2030. It is certainly inevitable that the electric vehicle will be the car of the future.

Reducing EV Energy Loss with Electric Steel Plate

The core parts of the EV include a motor, battery and car frame. EVs don’t have engines. Instead, the power that moves an EV comes from electricity stored in its battery.

An electric motor powers the wheels which move the car. To increase the output of the motor, the peculiar qualities of the non-directional electric steel plate has to be improved.

The output of the motor is expressed in the form of “speed of revolution x torque.” For a larger motor torque, the magnetic flux of electric steel, which is used as a core element of the motor wrapped with wire, must be high.

Also, to increase the output of the motor, the speed of revolution should be fast. This increases excitation frequency and iron loss, resulting in lower power efficiency. Therefore, in order to increase the motor characteristics, electric steel plate, which has low iron loss, should be used even in high-frequency territory.

In addition, for motors to revolve quickly, the rigidity of the electric steel plate, which is used as a rotor, must be high for it to avoid transforming. In other words, electric steel plate should be of a high quality to heighten the accelerating performance of EVs.

Material Technology That Overcomes the Limitations of EVs

One of the weaknesses of EVs is that the mileage per a single charge is short compared to diesel cars. To increase mileage, the charge rate capacity of the lithium-ion battery should be high.

The charge rate capacity is higher when more lithium-ion is available to be charged. Active materials with a wide specific surface area should be developed into cathode materials to increase the amount of lithium-ion charge for a higher charge capacity.

Also, as the demand for lithium-ion batteries has dramatically increased, the cost of lithium metal has skyrocketed due to its short supply.

Lithium salts are extracted from water in mineral springs and salt lakes like those in South America in a similar method as salt evaporation. This existing method is low in efficiency and production speed, and the produced lithium metal has a low purity of approximately 40 to 50 percent.

“LiSX” is a new method of lithium extraction that POSCO recently developed. This method can concentrate and produce lithium with more than 99.9 percent purity in a low concentrated salt lake with a lithium content of 20 parts per million (ppm) in eight hours.

The construction period of this type of production facility is short, and lithium can be produced immediately after the facility begins operation. As a result, this method is a good response to the recent changes in lithium demand.

△Renault’s Eolab—an EV that uses high-strength steel and magnesium sheet

To increase driving efficiency of EVs, the weight of a car frame should be reduced. A direct way to do this is to lighten the weight of chassis and car body materials.

steel is suitable as a chassis material to lighten the weight of automobile components and heighten the performance of crashworthiness, as it has a high formability and is two to three times stronger than general steel.

Aluminum and carbon-complex composites are currently used for parts of the body of the car, but magnesium alloy plates, which are far lighter than aluminum, are receiving attention as a future material.

There is still a need for further development and technical improvement of the electric vehicle to secure its place as the car of the future. In order to heighten the performance of the EV, material technology that can improve materials for the car frame, motor and battery is even more necessary than the development of machine techniques.

Material companies will no doubt help to improve the global traffic environment and further, work as advanced guards to improve the environment of the earth. This is why the performance of POSCO—an integrated material company—is greatly expected to make such contributions.

Written by science technology columnist Dr. Junjeong Lee

The opinions expressed in this POSCO Report piece are the author’s own and do not necessarily reflect the views of POSCO.

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