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.

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.

Don’t miss any of the exciting stories from The Steel Wire – subscribe via email today.

Cross-Industry Collaboration for Unsurpassed Innovation
At CES earlier this month in Las Vegas, the world saw how traditional and non-traditional technology industries partnered and collaborated on ways to do business and address global issues, from making roads safer to preventing illnesses. These cross-industry collaborations are becoming increasingly common and can be structured to meet multiple objectives while spanning multiple industries.
The trend of cross-market relationships is also emerging in the steel and automotive industries, specifically in the areas of lightweight vehicles, the latest innovations in steel applications and eco-design for automotive materials. Recognizing this, POSCO is making multiple efforts to step out of the oft-confining boundaries of industry and expand its services to other markets.
Among these efforts are collaborations within POSCO Group. POSCO TMC, for example, is partnering with the Group as a specialist of motor cores for electric automobiles while POSCO ChemTech is affiliated with a company specializing in battery materials. Such collaborations are exactly in line with POSCO’s policy of building a sturdy total solution-based revenue mode.
“POSCO is no longer simply a steel provider. It is a ‘total solution partner’ that works from A to Z for the complete production of automobiles,” noted POSCO executive director Wonki Kim at POSCO’s press conference at the Cobo Center in Detroit. “It will play the role of being the best assistant in reaching eco-friendly, lightweight vehicles while providing values that take a great step forward through utilization techniques such as figuration and welding based on high-quality materials as well as commercial support.”

Paving the Road to Sustainability with Steel Sheets

POSCO’s technology on display at NAIAS demonstrates the steelmaker’s unique raw materials for future eco-friendly automobiles, such as hot press forming (HPF) and PosM Steel.
The latter of the two is considered a “dream material,” as its intensity is five times stronger than other steel in terms of machinability, while it can withstand up to 100 kilograms per square millimeter. Therefore, it proves excellent in impact absorption and increased safety—one major focus regarding future automobiles.

About 30 high-strength and lightweight steel products, including POSCO’s original products, are being exhibited at this year’s NAIAS. POSCO plans to attract the attention of global automobile companies by presenting its auto body made with the world’s best car sheets.

Likewise, POSCO aims to address global automakers’ purchasing needs at NAIAS by revealing the most ideal steel plates for automobiles. The weight of this steel itself is about 26.4 percent lighter compared to mid-sized vehicles and has been verified in terms of safety. It also gives off fewer emissions of carbon dioxide compared to electric vehicles made with one-third the gravity of aluminum in comparison to iron.

POSCO “Driving” the Auto Industry Since 2010
Despite POSCO’s recent efforts to help construct the automobiles of the future, the company has been pursuing automotive endeavors for a while now. In fact, POSCO has been working toward the successful development of a sustainable electric car body ever since 2010. In just two years, POSCO launched PBC-EV, a safe, lightweight car body developed especially for electric vehicles. The weight of the PBC-EV was reduced by 26 percent compared to cars of the same size with internal combustion engines.
In addition, the car body possessed high-strength properties and received a score of five stars from EURONCAP and achieved a “Good” safety rating from IIHS. The development of PBC-EV was a result of applying the world-class Ultra High Strength Steel (UHSS) to over 40 percent of the material and optimizing advanced construction methods such as HPF (Hot Press Forming).
Other milestones were reached in 2012 when POSCO signed a joint development agreement with Renault-Samsung, and again in 2014 when the company joined in on the EOLAB production project with the French automaker. The revolutionary concept car boasts a super-efficient fuel economy of 100 kilometers per liter, thanks to its extraordinary lightness—a key to the development of future cars—enabled by the use of its state-of-the-art, high-strength steel and special magnesium panels developed in conjunction with POSCO.
Then, last year, the steelmaker held the POSCO Automobile Solution Seminar, which was attended by over 250 representatives from automotive part manufacturers, universities, R&D institutions and finished carmakers including GM Korea, Ssangyong Motors, and Renault Samsung Motors. The seminar focused on promoting POSCO’s latest technologies for automobile solutions and featured two stripped down vehicles that showcased the latest automotive design trends and materials.
Now, in 2016, POSCO continues to be at the forefront of the development of the auto industry of the future. Although it’s impossible to know for sure what the future of the automobile market will look like, one thing is for certain, according to POSCO’s managing director, Wonki Kim: “Steel is still the ‘Best Solution’ and it will continue to be in the future.”

Related Articles
POSCO Announces New Steel Sheets at Detroit Motor Show
Renault’s EOLAB Shines at 2015 Seoul Motor Show
What are Automobiles Made of?

Be sure you never miss any of the exciting steel stories from The Steel Wire by subscribing to our blog.

POSCO will exhibit its technology for the first time as a steelmaker at the North American International Auto Show in Detroit on Jan. 11 to 24.

TWIP is the “dream material” that has improved its intensity and machinability, and has been produced by POSCO for the first time as a steelmaker, representing the unique power of POSCO’s technology.

This steel’s intensity is five times stronger than other steel in terms of machinability, while withstanding up to 100 kg per mm². Therefore, it proves excellent in impact absorption and increased safety. This technology can be applied to bumper beams of automobiles. Many competitors have tried to develop TWIP, but failed to deploy it on a commercial scale.

HPF steel is hard to process when the intensity level exceeds 1.5 GP. To counteract disadvantage, HPF has increased its machinability through heat treatment. This product can be applied to center pillars to protect passengers from external accidents. POSCO has become the world’s first steelmaker to successfully produce a product in level of 2GPa. This product was first introduced as Renault’s 1 L concept car at the Paris Motor Show in 2014, and it earned favorable reviews.

POSCO will also showcase the 1GPa-TRIP, a recently developed steel with high intensity and ductility, and the PosM_XF (extra formability), the next generation TRIP with improved machinability.
For the NAIAS, POSCO aims to attract global automakers’ purchasing needs by revealing the most idealistic steel plates for automobiles.

About 30 high-strengthened and light weight products including POSCO’s original products are being exhibited at this year’s motor show. POSCO plans to get attention from global automobile companies by presenting the auto body made with most ideal and the world’s best car sheets.

The weight of the steel itself is about 26.4 percent lighter compared to mid-sized vehicles and has been verified in terms of safety. It received a five-star safety rating, as well a “good level.” which is the highest level possible, for internal performance evaluation conducted by Europe and North America’s automobile collision evaluation Institute, Euro NCAP and IIHS.

In addition, the Life Cycle Assessment (LCA), which measures the amount of CO2 discharged throughout the entire life cycle from material production to recycling, showed that the internal combustion engine body was 50 percent lower, and average electric car emission was about 9 percent less. It also gives off fewer emissions of CO2 compared to electric vehicles made with one-third the gravity of aluminum in comparison to iron.

POSCO currently supplies automobile steel sheet to the automobile manufacturers and component manufacturers, including the global top 15 companies such as Toyota, Volkswagen, and GM through 10 automobile production plants and 24 machining center. POSCO has proven its quality excellence by receiving “This Year’s Supplier” from the world’s leading automotive companies such as Toyota and GM.

POSCO is planning to expand 70 percent or more of World Premium (WP) steel sheet sales ratio by not only supplying products but also providing use of technologies such as molding and welding for customer’s best utilization of certain products through the development of solutions marketing activities.

Don’t miss any of the exciting stories from The Steel Wire – subscribe via email today.