Reflecting the lightweighting trend of the auto industry and the rise in the level of seat frame strength for stability, the importance of lightweighting and strong seat frame material and technology is becoming increasingly apparent.  

POSCO Newsroom covers the scene where future cars are created— with DSC’s unceasing efforts in innovating lighter and stronger cars and POSCO, the manufacturer of “Giga Steel”, also referred to as “Dream Steel” that materializes these efforts.

Fuel Efficiency vs. Resistance to Impact

Which is a better pick? A light car for fuel efficiency? Or a car highly resistant to impact? The answer is both. Beyond the economic advantage of the consumer, reinforced environmental regulations along with raised awareness of environmental impact has caused the automotive industry and its consumers to regard lightweighting as a priority. Yet, it is also inevitable to seek out a strong car for passenger safety.

DSC has prioritized developing ultra-lightweight, high-strength seat frame, what all drivers and finished auto manufacturers yearn for. The first-generation through currently commercialized third-generation frame has seen through quite an innovation. DCS’s third-generation seat frame has decreased in weight by 21% compared to the first while the strength improved highly with the application of POSCO’s Giga Steel.

“Automotive lightweighting and structural stability are essential requirements that shouldn’t be overlooked. DSC is constantly innovating the seat frame’s rate of stability through lightweighting while maintaining the highest level of strength.” (Chan-gi Jo, the head of R&D Center at DSC)

DSC’s Unstoppable Drive for Innovation: Giga Steel and Low-Temperature Welding

To figure out how ultra-light and high-strength seat frames are originated, POSCO Newsroom paid a visit to DSC’s Head Office located in Gyeonggi-do, Korea. State-of-the-art equipment galore at the Pilot building where skilled engineers run elaborate tests and benchmarking while labs are running varied simulations based on blueprints.

Dong-su Kim, the head of of Global Support Office at at DSC referred to POSCO’s Giga Steel (resisting pressure of one gigapascal) as one of core solutions to DSC’s ultra-light, high-strength seat frame. By applying POSCO’s ultra-strength Giga Steel, less amount of steel performs the same amount of intensity. Thus, a lighter, stronger, and safer seat frame can be produced in comparison to what regular steel can offer.

DSC’s exclusive low-temperature welding technology that enables its unique high-strength seat frame was observed with the naked eye. Its low-temperature welding drastically improved regular laser beam welding that is less cost-efficient and difficult to modify. Through establishing its own seat frame technology, exclusive to the domestic market, DSC increases both the quality and stability while being adaptive to the changes in automotive manufacturing technology.

“DSC has achieved excellence through Giga Steel and low-temperature welding. It’s already a brand that is trusted by international automotive companies such as Hyundai motors, Ford, and Subaru. We are aiming to promptly accommodate the needs of future sustainable car industry through even more lighter and stronger seat frames by focusing on developing next-generation lightweight, high-strength seats.” (Dong-su Kim, the head of Global Support Office at DSC)

The Perfect Pairing: POSCO’s Giga Steel in DSC’s Seat Frame

POSCO’s Giga Steel is an ultra-high-strength steel plate that can withstand 1,500 units of 1-ton-worth compact cars on the size of a palm. Stronger products can be crafted with lesser weight, making it especially popular as a lightweight automotive material. DSC is also actively adopting POSCO’s Giga Steel as the ultimate lightweight and high-strength material for seat frames.

Recently, DSC and POSCO have taken their technological cooperation to the next level—next-generation ultra-lightweight seats making maximum use of Giga Steel. Already captivating the auto industry, this new seat frame evolution prides in using both companies’ cutting-edge technologies.

“DSC is currently supplying its high-strength seat frames to global car manufacturers with its production base in 20 locations around the world, including United States, China and Europe. POSCO will continue to build on its Solution Marketing activities with DSC, further expanding Giga Steel’s market share for seat frames.” (Jong-gyu Kim, POSCO Automotive Materials Marketing Office)

POSCO Newsroom has observed endless innovations in the making of light and strong cars, and heard stories of people who make dreams come true right at the scene. With DSC seeking perfection even in unseen areas, along with POSCO, the dream material, “Giga Steel” creator grasping the hidden needs of the manufacturer and the end consumer, the future of their bonded efforts is highly anticipated.

Lightweight is compulsary for future electric vehicles(Source: MEGAEV)

The Lighter the Car, the Further it Goes

Vehicle electrification refers to the reduction or removal of the internal combustion engine and replacing it with an electric motor and battery. While electrification helps reduce global warming emissions, the batteries used in electric vehicles are too large in volume and weight, which limits the number of batteries a vehicle can carry. This leads to the critical drawback of an EV – that it cannot travel far on a single charge.

Placing more batteries in the vehicle to increase the driving range will also increase the vehicle weight, causing a further decrease in energy efficiency. So what are the ways to improve efficiency in electrified vehicles?

Material Matters

Reducing the weight of the materials used in the vehicles can be one solution. With government subsidies, EV manufacturers have been using carbon fiber composite materials and aluminum, which are lightweight but high cost materials to reduce vehicle weight. As EVs become more common and manufacturing cost becomes a growing concern, steel is expected to become an attractive alternative as a more economical material.

Also, since the battery is highly flammable upon impact, the ultra-high strength steel is expected to become more widely used in electric vehicles for an added layer of protection against collision. As provider of various steel solutions for automobiles including the ultra-high strength ‘GIGA STEEL’ and magnesium panels, POSCO is accelerating its efforts to support the changing needs of the auto industry to provide durable and lightweight solutions.

Limited performance of battery for electric vehicle can be improved by increasing the density of battery(Source: Los Angeles Times)

Battery, the heart of the EV

Electric vehicle gets its propulsion from batteries. The current issue of the battery is developing the battery with higher density. Like any other batteries, batteries for EV also have a lower density of energy compared to petroleum fueled energy. Basically, the energy density of battery is decided by the ratio of the substances (Lithium, Nickel, Cobalt and Manganese) composing cathode.

Due to the fluctuation of the price, increasing the ratio of Nickel is the new strategy to maximize the efficiency. In the recognition of this trend, POSCO ESM, one of the affiliates of the POSCO that manufactures the material for cathode and anode for batteries, developed PG-NCM (short for POSCO Gradient-Nickel Cobalt Manganese, applied NCM811 that contains more than 80% of Nickel) to prepare the future battles of electric battery field.

Efficiency of electric vehicle is still controversial(Source: Cardiff University Research)

What Drives the EV?

Another factor that can help increase the efficiency of an electric vehicle is the driving motor, which acts as an engine that moves the vehicle. Efficiency of the driving motor can be increased by reducing the thickness of the steel layers in the motor core, a key component of the driving motor. POSCO’s Hyper NO and self-bonding technologies enable production of 0.15mm ultrathin steel layers and high efficiency motor core components.

Efficiency of electric vehicle is still controversial(Source: LGNewsroom)

Future of Mobility

As public transportation becomes more convenient and the sharing economy becomes more widespread, it is becoming easier to “share” a vehicle whenever needed. With increased automation, we will see more vehicles that are simplified to accommodate 1, 2 persons or 8-person shuttles that are optimized for the shared economy. The race to provide the finest materials and components to accelerate the shift of paradigm of mobility has already begun.

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.

Globally, shipping accounts for 15 percent of N0x emissions, 8 percent of S0x emissions and 3 percent of greenhouse gas (GHG) emissions, while aviation accounts for just 1.5 percent of GHG emissions. Overall, emissions including GHG are increasing with booming trade and industrial activity, and policymakers are facing mounting pressure to deal with the crisis.

SEE ALSO: The Changing Waves of the Shipping Industry

Urgency of Clean Air

Experts found that in 2015, 6.5 million people died prematurely as a consequence of air pollution, with 92 percent of the deaths occurring in developing countries such as India, China, Pakistan, Bangladesh, Madagascar and Kenya. In these countries, up to 25 percent of all deaths are pollution related. In India alone, 2.5 million people died from pollution, China saw 1.8 million pollution-related deaths and even in the U.S., more than 155,000 deaths were linked to air pollution.

In China, fog-like smog covers cities. (Source: South China Morning Post)

As a result, governments and international organizations all over the world started implementing environmental policies under growing pressure from well-informed citizens. For example, China has shut down a number of factories across the country and has policies in place to heavily regulate emissions as part of their “Beautiful China” initiative. Also, the International Marine Organization (IMO) announced it will tighten the international sulfur cap for shipping emissions from the current 3.5 percent to 0.5 percent by 2020.

Such initiatives are great first steps, as making the switch to cleaner marine fuels such as low-sulfur fuel will lead to 137,000 fewer premature deaths caused by air pollution and 8 million fewer cases of childhood asthma. However, with increasingly stringent environmental regulations, the shipping industry is eyeing more sustainable and renewable fuel options.  

Liquified Natural Gas

Currently, the most common and feasible option available for minimal emissions is liquified natural gas (LNG). Many shipping companies are embracing this option ahead of IMO’s 2020 emissions cap as LNG emits zero S02 and particulate matter, and up to 25 percent less C02 and up to 90 percent less N0x.

As a result, major oil companies are channeling their resources towards LNG production and manufacturers are opting for LNG-powered ships to lower their life cycle emissions. However, the downside to LNG as shipping fuel is that LNG tanks require more space on vessels. They also add considerable weight, meaning the vessel will use up more fuel.

LNG is the most feasible option for shipbuilders and manufacturers looking to lower emissions. (Source: Oil Industry Insight)

This is where steel can play a vital role in equipping shipbuilders with the lightest and strongest material options. This year, Hyundai Mipo Dockyard will build the world’s largest LNG-powered bulk carrier capable of yielding 50,000 tons of cargo, which is seven times more than existing LNG carriers. The company chose to build their vessel using POSCO’s High Manganese Steel, which is lightweight, tough, super strong and is able to facilitate the storage temperature of LNG at -162℃. Not only that, the steel is also cost effective when compared to other material options for ships.

SEE ALSO: POSCO’s High Manganese Steel to be Used for the World’s Largest LNG-Powered Bulk Carrier

Renewable Energy

Another company making exciting waves in the shipping industry is Eco Marine Power. The technology company is developing an alternative energy solution called Aquarius Marine Renewable Energy that will allow cargo ships to run on wind and solar energy. Rigid sails and solar panels will be placed on the exterior of cargo ships to directly generate and store energy and energy levels can be monitored via a computer-based system. This year, researchers are planning to put the system to the test with a Japanese shipping company to monitor the system’s performance, energy generation and the vessel’s energy consumption.

Eco Marine Power will put its energy solution to the test this year. (Source: Eco Marine Power)

Last year, Chinese shipping company Hangzhou Modern Ship Design & Research Co launched a cargo ship powered by an electric battery powertrain. The 2000-ton capacity vessel runs on two 160 kW electric propellers, supercapacitors and lithium batteries that provide a range of about 80 km per charge. For now, it is being used for short trips to carry coal up and down the Pearl River in Guangdong Province, and at each end, the vessel only takes about 2 hours to charge.

China launched the world’s first fully-electric cargo ship. (Source: China Minutes)

Again, the challenge for companies experimenting with renewable energy options will be dealing with the additional weight of generators and battery packs. The feasibility of sustainable cargo ships lies in the vessel’s energy efficiency, and heavier vessels will take up too much energy. As 90 percent of all trade goods cross the sea at one point in their life cycle, it will be impossible to decrease shipping activities. Instead, manufacturers will have to partner with solutions providers like POSCO for high-performing, lightweight materials to achieve clearer skies and a future of green shipping.

Cover photo courtesy of Global Economic Dynamics.

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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Although wire rods are not always in the spotlight, they are widely used in many parts of a car. Steel wire rods are processed into parts for the steering and suspension systems, tire cords and bearings.

However, not all wire rods are the same, and improvements in production technologies can increase automotive performance, safety and cost-effectiveness. POSCO’s world premium steel wire rods provide such solutions to its automotive partners as the global demand for automotive wire rods continues to grow.

Take a look at the video below to see why more and more automakers are choosing POSCO’s wire rods, and where they can be applied.

Wire Rods in the Steering System

The steering system is what allows the wheels of a heavy vehicle to move in various directions and angles, with little force exerted by the driver. If the driver were to steer the road wheel directly, he/she would have to apply 16 times more effort. Fortunately, the movement of the steering wheel passes through the steering system of pivoted joints to the road wheels, which minimizes the burden of labor on the driver. The most common type of steering system is the rack and pinion, pictured below.

Wire rods make up the steering system of a car. (Source: Tires and Parts)

Traditionally, wire rods used for the pinion shaft, rack bar, ball housing, tie rod and tie rod end of the steering system have to be heat treated twice during production. POSCO developed a way to take out all the heat treatment from the production process, allowing manufacturers to cut costs significantly and reduce unwanted emissions.  

Wire Rods for Springs

Automotive springs are part of the suspension system of a vehicle, which determines the level of control the driver will have, as well as the level of comfort. The spring coils compress and elongate along with the movement of the wheels to absorb shock and keep the car body level.

Coil springs are part of the suspension system of a car. (Source: Pakwheels)

As such, the wire rods that make up the suspension system have to have high tensile strength and fatigue resistance. POSCO’s wire rods for automotive springs are made of ultra-clean alloying steel and have a 2.3 GPa tensile strength versus the average 1.9 GPa of traditional wire rods. When applied to the engine valve springs and coil springs for suspensions and stabilizer bars, it enhances the overall performance, safety and lightweight features of the vehicle.       

Wire Rods for Tire Cords

Wire cords undergo an extensive drawing process to be processed into tire cords, also known as tire belts. Tire cords are important because they act as the chassis of the tire, giving it strength and resistance against punctures. It also allows the tire to stay flat for maximum contact with the road.

POSCO’s wire rods during the production process. (Source: World Steel Association)

The quality of tire cords lies in its strength, elongation and stiffness, and require especially clean and high-strength steel to produce. POSCO’s wire rods for tire cords are also highly workable for producing extra-fine wire, meaning car manufacturers get the added benefit of lightweight along with enhanced safety and performance.

Wire Rods for Wheel Bearings

Wheel bearings are under a lot of pressure, literally. It bears the weight of the vehicle so that the wheels can turn as smoothly as possible with little friction. If a car’s wheel bearings don’t function properly or wear out, the tires can rub against the axle, the rubber can burn due to friction, the wheels can malfunction and cause screeching sounds. It is important for the bearings to be highly wear and fatigue resistant to minimize work hardening, crack and deformation. POSCO’s innovative production technology includes numerous tests and quality checks to ensure that wire rods for bearings are in perfect condition.

Wheel bearings bear the weight of the vehicle so tires don’t have to. (Source: MOOG Suspension Parts)

Recently, Research and Markets predicted a compound annual growth rate (CAGR) of 3.50 percent for the global stainless steel wire rod market from 2017 to 2021. This is a telling sign that automakers will continue to seek high-quality wire rods in the midst of growing investment in electric and autonomous vehicles. Now with its second overseas facility up and running, POSCO will continue to meet the global demand for world premium automotive materials and provide innovative solutions to its partners.  

Cover photo courtesy of Steel Intelligence.

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In this spirit, The Steel Wire highlights the innovative use of metals in household appliances and electronic devices from air conditioners and cameras to laptops. Read on to see how innovative applications of metals have the power to present a new, more efficient way to live.

Breeze-Free Air Conditioner with Metal Cooling Panel

There may have been those even in the heat this past summer who didn’t want to use air conditioners due to direct blasts of cold air. Here’s good news: Samsung’s “breeze-free” air conditioner, Q9500, maintains a stable room temperature without blasting a single column of strong and direct wind.

How can air conditioners be “breeze-free”?

The company used a metal cooling panel and a micro hall-based air current passage system that constantly changes the direction of the air. Cold air is sent through 135,000 tiny holes and the short airways can reduce energy use by 65 percent. Also, climate control settings can be adjusted directly via smartphones using IoT technology based on weather data.

Samsung’s breeze-free air conditioner, Q9500, comes with metal cooling panels and 135,000 micro holes which maintain a stable room temperature without blasting strong and direct cold air. (Source: Flickr)

The even distribution of cool air allows air conditioners to naturally blend in as part of any space or room it occupies and eliminates the discomfort of direct, cold air.

Lightweight & Durable Cameras with Magnesium Construction

Global camera brands have long been searching for ideal materials to meet consumers’ needs for lightweight, mobile and durable cameras. For this reason, one of the prestigious features of top-end cameras in the market today is magnesium construction. This is due to magnesium’s lightness, strength and ability to shield users from electromagnetic waves. Magnesium is, in fact, the lightest structurally-used metal in the world with a greater strength-to-weight ratio than that of aluminum. This allows magnesium electronics bodies to be thinner and lighter.

For instance, the exterior shell of the Nikon D3 is made of a magnesium alloy. The product’s magnesium-alloy camera frame effectively protects the camera from invasive dust, moisture and electromagnetic interference with a self-diagnostic shutter mechanism tested to exceed 300,000 cycles.

The Nikon D3s’ magnesium-alloy camera frame effectively protects the camera from invasive dust, moisture and electromagnetic interference.(Source: Flickr)

Ultra-light Laptop with Duralumin

Over the years, new technologies have pushed PC makers to build ever lighter and thinner laptops with premium materials. Samsung also started to pursue metals that are lightweight yet durable. In the past, the company used magnesium-lithium sheets from overseas suppliers in order to keep their laptops lightweight. The sheets had good machinability but low hardness, making them vulnerable to dents. In order to overcome this, the company turned to POSCO’s specially designed magnesium sheets, duralumin*, known for its high-strength and lightweight qualities. In 2016, POSCO began supplying its magnesium sheets for the Notebook 9 that is just 840g. In 2017, the Samsung Notebook 9’s weight was brought down even further to 799g.

These magnesium sheets, made with a rapid solidification process that is capable of precision control, are tempered several times and undergo special heat treatment until they reach a final thickness of 0.5mm. POSCO succeeded in increasing the surface hardness by more than 20 percent and the yield strength by more than 50 percent, compared to its competitors, while still maintaining a high level of machinability.

Such advancements in lightweight and high-strength materials have allowed people the flexibility, mobility and convenience to work on the go and reduce inefficiencies.  

*Duralumin is a high-strength aluminum alloy made by mixing copper, magnesium and other elements.

POSCO supplies magnesium sheets for Samsung Electronics’ 2017 model of Samsung Notebook 9 that touts ultra-light, high-strength metal materials. (Source: Samsung Newsroom)

In today’s world, it’s hard to imagine life without electronic appliances and devices that provide a better quality of life. In a way, the invention and evolution of such products have redefined the way people live, work and play. The application of innovative materials has sped up and continues to allow manufacturers to add value to their products.     

Aging Water Pipeline Systems Around the World

Outdated water pipelines systems such as prestressed concrete cylinder pipelines (PCCP), lead pipes and corrosive iron pipes are causing problems worldwide.

PCCP is common throughout the U.S. They are large in diameter, meaning that when they fail, it can be catastrophic. PCCP failures have ruptured and leaked, cracked and dented, or otherwise ceased to hold up to the high capacity, high-pressure needs they were once installed to meet.

Why are they failing? Generally speaking, PCCP was not held to high standards during 1970s-era installations. The reinforcing wires used within those pipes were not manufactured with enough thickness, ultimately leading to corrosion and brittleness as the pipes reach the earlier-than-expected end of their usefulness.

An example a ruptured PCCP (Source: Hazen)

These pipes are failing wherever they are in use – all over the United States and all over the world. Florida and Maryland have been forced to handle catastrophic failures. In California, PCCP in need of repair or replacement cost USD 40 million for 4.5 miles of relining work. The overall cost of fixing pipes underneath southern California is estimated at $2.5 billion.

That’s just a drop in the bucket, looking at the overall cost of repairing or replacing PCCP in the U.S. The U.S. Environmental Protection Agency and American Water Works Association estimate that national replacement and repair work could cost $40 billion.

Governments do not want to make the same mistake again while replacing or repairing water pipelines, and there is a clear need to choose a material that can withstand time, pressure and environmental stresses.

The Solution: Stainless Steel

Stainless steel is the material of choice in modern pipe installation and replacement projects.

As an example of how this material can offer great benefits, Tokyo’s Bureau of Waterworks began replacing leaky, old cast iron pipes with stainless steel in the 1980s. The material was chosen because of its strength and its well-known resistance to corrosion. All of the pipes in the water distribution system were replaced with stainless steel by 2012, drastically reducing water loss.

A worker inspects a steel pipe during pipe replacement in Japan. (Source: World Steel Association)

Choosing stainless steel for this kind of work is becoming a global standard. Seoul is another major city that replaced its outdated water pipelines with stainless steel. Around 96 percent of Seoul’s pipes were replaced by 2013, and the remaining pipes will be replaced by 2018.

In Taipei, pipes installed before 1979 were mostly made of lead- causing health and safety concerns for Taipei’s citizens. Over 70 percent of existing lead pipes were replaced with stainless steel by the end of 2016, and more replacements are underway.

Why Stainless Steel is Superior

It is clear that PCCP is not an option many would consider, given the huge costs related to replacing it. Even with the vast material options available, there is a clear reason governments and agencies are choosing stainless steel for waterworks systems.

High-density polyethylene (HDPE) is chemically resistant and lightweight, like steel, but can easily be degraded by sunlight. Because waterworks systems need a long lifespan, it does not make sense to choose a material that can be affected so heavily by environmental factors.

Ductile iron is an option, but is generally rejected because it requires more infrastructure to work, owing to its weight and short laying lengths. More and larger support foundations are required to hoist systems made from this heavy material. Ductile iron requires special lining when used in waterworks systems, as it can be affected by iron bacteria and precipitation.

High-grade stainless steel is naturally resistant to corrosion. It offers high strength and pressure resistance. It is a material that maintains resistance to microbes, and can be manufactured to resist heat.

POSCO’s stainless steel, particularly duplex steel, is ideal for waterworks, for all of the above-mentioned reasons. POSCO’s Lean Duplex steel or PossSD features superior anti-corrosion and intergranular corrosion resistance. It is employed regularly for applications such as water pipelines, and sea-water and chemical equipment. Watch the video for more details.

As cities see PCCP and other old pipe systems failing, materials like PossSD will ensure that replacement water pipelines do not suffer the same fate.

When creating new pipelines, and bringing old systems back to life, stainless steel is the best choice. It is lightweight yet strong, resistant to microbes, corrosion and other damage, and it can withstand all the pressures, temperatures and elements that exist within a pipeline system.

As the majority of the world’s pipeline systems have or will be reaching the end of its lifespan, cities will have to plan ahead and incorporate the best possible materials to ensure clean and safe water delivery, as well as to minimize future costs for repairs and replacement. Stainless steel is already relining or replacing outdated pipes all over the world, and will help governments eliminate safety and budget concerns.

Cover photo courtesy of Overeem.

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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CIAPE is the largest automotive parts expo in China, and has been sponsored by China’s Ministry of Commerce since 2008. As many as 200,000 people participate in the event, including over 2100 companies around the world to exhibit various automotive products. On display this year were various electric vehicles, components, electronics and automotive parts and manufacturing facilities.

POSCO actively promoted POSCO GIGA STEEL at its exhibition booth where visitors browsed various automotive parts made of GIGA STEEL. Visitors were especially impressed with POSCO GIGA STEEL’s lightweight, cost-efficient and high-performance qualities, as well as POSCO’s production technologies.

Throughout the expo, POSCO introduced practical applications of its products including wire rods for automobiles, electrical steel sheets, stainless steel for various uses as well. Various automakers and parts makers could also experience POSCO’s steel mills and production processes through VR technology.

A total of 1,583 people visited POSCO’s booth over the 3-day period to browse the electrical sheets, wire rods and stainless steel products as well as automotive steel plates. In particular, as many as 1,020 people flocked to the GIGA STEEL Experience Zone where they could compare the hardness, weight and thickness of aluminum and GIGA STEEL.

POSCO also held 71 meetings with 188 potential customers from various sectors, including automakers and parts makers in China and promoted its GIGA STEEL and automotive World Premium Products (WPP) to potential business partners.

One of the visitors was Lee Jeong-hae, CEO of Sungwoo Hitech Yancheng. He said, “I was able to learn that GIGA STEEL is more effective in reducing weight than aluminum. I am truly looking forward to seeing more automakers use GIGA STEEL instead of aluminum.”

This was the first time POSCO attended the event, and hopes to use it to create momentum for increasing the sales of its World Premium steel products and automotive materials, and to expand its network of partners in China.

Cover photo courtesy of CME Shanghai.

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