Publication in Prestigious Journal: Recognized for Academic and Economic Value by Global Scientific Journal Nature Communications.

POSCO’s research paper on high-performance, low-cost GigaSteel welding technology, PosZET® GIGA, was published in the prestigious scientific journal Nature Communications on February 12.

* Nature Communications, a comprehensive science journal published by the Nature Portfolio, is recognized for its authority in materials science, among others (Impact factor of 16.6).

Automobile manufacturing relies heavily on the welding of various steel materials, where not only the inherent characteristics of the steel but also the strength of the welds are crucial. The welding technology developed by POSCO is expected to enhance the applicability of POSCO’s ultra-high-strength steel plates, GigaSteel, in automotive materials.

▲ The schematic diagram unveiled by the joint research team of POSCO and Changwon National University illustrates the formation mechanism of the fine microstructure in GigaSteel weld metal.

POSCO’s GigaSteel, boasting tensile strengths above 980 MPa, has traditionally utilized a substantial addition of nickel (Ni) for welding materials. PosZET® GIGA introduces a technology that replaces nickel with an optimal blend of niobium (Nb) and chromium (Cr) for the welding material (wire), creating a complex and dense network-like microstructure in the weld metal*, enhancing both strength and toughness simultaneously.

* Weld Metal: A portion of the weld area where the base metal and the welding material (wire) melt together during welding and solidify.

Utilizing PosZET® GIGA increases the bending fatigue strength of the joint by more than double compared to conventional methods and impacts toughness by approximately 15%. Applying this technology to manufacturing automotive parts such as chassis and frames can improve vehicle safety, as joints are less likely to break under repetitive impacts or temperature changes than when traditional welding techniques are applied. Additionally, as the enhanced performance of the welds allows for a reduction in steel plate thickness, vehicle lightweight designs can be accomplished. This new method costs about half that of the conventional approach, which primarily uses nickel.

In joint research with Changwon National University, POSCO has scientifically elucidated this technology for the first time globally. The study revealed the atomic-level impact of adding niobium and chromium on the microstructure of the weld metal. This research, acknowledged for its academic significance and commercial viability, has been published in the globally renowned journal Nature Communications.

PosZET® GIGA has recently received technical application approval from global automotive companies and is slated for use in actual automobile parts. POSCO plans to continue expanding the sales of GigaSteel utilizing this technology.

Such a description isn’t inaccurate considering POSCO has topped the WSD (World Steel Dynamics) competitiveness ranking for 10 years straight.

But it’s not enough — yes, POSO was and still is a top steelmaker, but the values POSCO is creating goes beyond the realm of steel products. To reflect this reality, the more accurate description of POSCO today is: “POSCO provides the most competitive solutions to the clients.”

l POSCO — More than Products

The day-to-day steelmaking operation involves: melting iron ore to produce molten iron and making steel products as per client’s requests, be it hot-rolled steel, cold-rolled steel, wire rods, thick plate steel, etc.

For POSCO, that’s not the end of the story. POSCO’s sales tactic distinguishes itself from other steelmakers in that, when a client places an order, POSCO doesn’t immediately jump into the production. Instead, POSCO thinks ahead considering the whys and the hows: why does the client want and need this product? What are the best manufacturing/welding/assembly technologies to serve that purpose so the product can thrive in the market?

Let’s say a client places an order for a wire rod. Ultimately, the client would like to produce large bolts with POSCO’s wire rod. In this case, what POSCO sells to the client is not just the wire rod. What POSCO does is to sit down with the client and discuss the details of the end use: where will the bolts be used? POSCO thoroughly reviews the technologies involved, before heading straight into the production, so that the product can serve its best purpose.

If the bolts were intended for a steel structure, POSCO researches what joints will be connected, figuring out how the client can produce the most solid and durable bolts with POSCO’s wire rods. POSCO’s business approach is to provide the best possible solution for clients’ competitiveness, not just POSCO’s.

l POSCO Global R&D Center Spearheads Client Solutions

What enables providing POSCO solutions to clients? It’s the years of accumulated research on various properties and characteristics of steel materials. Currently, POSCO’s research facilities are located in Pohang, Gwangyang and Songdo: Steel Products Research and Process Engineering Research Group in Pohang; and Automotive Steel Application Center in Gwangyang.

Of all POSCO’s research facilities the Steel Solution Research Lab in Songdo, Incheon spearheads client solutions.

▲ POSCO’s research facilities

Over 80% of the researchers at POSCO’s Steel Solution Research Lab are Ph.D. researchers across various fields such as machinery, materials, architecture, civil engineering, etc. At POSCO’s cutting-edge, state-of-the-art research facilities, the company develops top solutions for clients from various industries including automotive, home appliances, electrical steel sheets, stainless steel products, construction, ships, machinery, pipelines, etc.

To optimize its capacity to develop client solutions, the Steel Solution Research Lab in Songdo restructured its departments into the following four groups this year: Materials forming research; Materials performance research; Steel structure research; Welding and Joining research.

In addition, the Steel Solution Research Lab collaborates with the marketing department in Seoul as well as with the Steelworks in Gwangyang and Pohang, playing a role in developing customer solutions, support, and timely supply of solution products.

l POSCO Solution Targets Client Success

The recent collaboration with Austem, an auto parts manufacturing company, is a good example of the solution development at POSCO Global R&D Center.

Austem provides key auto products such as chassis, body, steel wheel, and seat — through domestic and overseas businesses, Austem has annual sales of over 400 billion KRW. Austem has been POSCO’s long-term client since 1990, and the company shows a solid growth record through its existing products as well as new technologies.

As the auto market shifts towards sustainability, efforts are being made to make more eco-friendly cars such as electric vehicles and to reduce car weight. In such milieu, lightweighting auto parts such as suspension which absorbs the road impact to enable stable driving emerged as an important factor.

Despite the global tendency where automakers opt for aluminum to lightweight suspensions, POSCO has been focusing on developing steel suspension since 2016, through its partnership with Austem.

The two companies applied GIGA STEEL to suspension parts — conventionally, giga-grade steel was never applied to suspension. POSCO’s new approach led to an optimal design technique to secure lightweight without compensating the current level of performance.

Per suspension type, the weight was reduced by 14.3% to 20%, thereby securing a steel solution that satisfies the suspension stiffness, strength, and fatigue performance.

With the new GIGA STEEL suspension, Austem is pioneering a new market where the product is being positively received in the global market.

Dong-Yoon Seok, a Senior Researcher at the Materials forming research group at the Steel Solution Research Lab, said, “To verify the performance of the product, we went through countless prototypes and tests at the R&D center and the Austem’s production lines.” He added, “Collaborating with a competent client and meeting the goal we’ve set was truly rewarding. That’s the type of solution development we aim for.”

▲The POSCO-Austem partnership replaces aluminum with GIGA STEEL for suspension.

Seok, also remarked, “The long-term partnership between the two companies helped build mutual trust which made the whole solution development process much easier. That was one of the big contributing factors for the good result.” — his remark signifies when developing solutions for client success, what POSCO focuses is the long-term success, not the short-term.

As POSCO contributes to improving clients’ technology and sales channels through its solution activities, POSCO’s high-quality steel products are being sold with the most optimized performance. This has distinguished POSCO from other contenders in the industry and that’s the path POSCO will continue to follow.

POSCO isn’t satisfied with simply making the world’s most competitive steel products. Instead, they want to be a steel company that offers the most competitive solutions to their clients.

※ At the time of Austem’s overseas expansion, POSCO’s Global Platform Business (GPB) program supported its entry into China. GPB was created to help partner companies expand overseas. To supply auto parts to China’s key automakers, Austem signed a joint venture with POSCO and established three production facilities in Suzhou (2008), Yantai (2014), and Wuhan (2016).

– Finding the Hidden POSCO! –

Let’s begin!

① GIGA STEEL — Stronger, Lighter and Better for the Environment

POSCO developed GIGA STEEL, stronger and lighter than competing materials like aluminum and carbon fiber reinforced plastics (CFRP). Withstanding over 100 kg on 1mm2 space, GIGA STEEL builds stronger car bodies, suspension and battery packs making electric vehicles (EVs) safer for the public. Three times stronger and yet 3 times thinner than aluminum, it vastly lightweights car bodies.

With such strength, the GIGA STEEL effectively absorbs and disperses shocks in the event of an accident. It minimizes the shock impact thereby protecting the passengers as well as the batteries. Lighter but sturdier cars were made possible through POSCO’s GIGA STEEL.

GIGA STEEL is also eco-friendly as it helps protect the environment by reducing the cumulative CO2 emissions of cars by about 10%.

② Steel in the Tires! POSCO’s WTP Tire Cord Steel

Though invisible, steel is what makes car tires more durable. POSCO’s WTP (World Top Premium) tire cord steel is hidden in tire chords one of the many essential tire components. POSCO’s WTP refers to a line of products that enhance clients’ competitiveness with its high technology. POSCO’s WTP steel wire for tire cords are highly regarded – it improves stability and while minimizing the tire weight.

And it’s produced by twisting high carbon steel wire rod into a fine wire of 0.4 to 1.15mm in diameter. To withstand various dynamic loads on the vehicle, the tire cord steel undergoes rigorous quality control.

③ For Drive Motors, the World-class Electric Steel Hyper No

A motor is a key component of EVs. It boosts fuel efficiency and the performance of EVs. The function of drive motors in EV is that of an engine in gas vehicles – it allows the driveshaft to rotate via electric current. Highly efficient drive motors must be equipped with electrical steel plates with minimal power loss. POSCO has developed just that – the world-class electric steel plate, Hyper NO. Hyper No is used on high-efficiency motors.

When converting electricity into rotating energy, energy loss is inevitable. POSCO’s Hyper NO effectively minimizes the energy loss, thereby increasing energy efficiency – by over 30% than conventional products. To maximize motor efficiency, POSCO increased the magnetic flux density and successfully minimized energy loss. Thanks to POSCO’s Hyer No, an ultra-thin electric panel, as thin as 0.15mm, with minimum energy loss became a reality.

The ‘self-bonding’ technology POSCO developed recently applies coatings to the surface of electric steel plates, whose function is similar to that of glue. Unlike welding, POSO’s self-bonding technology retains the innate electromagnet characteristics of electric steel plates, which also connects to the improved motor efficiency. The self-bonding reduces energy loss by over 10 % compared to the conventional welding technique.

④ Secondary Battery Materials – from POSCO CHEMICAL!

Unlike disposable primary batteries, secondary batteries can be recharged and reused repeatedly. Lithium-ion battery, an essential component of EVs, is a type of second batteries. Besides EVs, it is a popular choice for many consumer electronics such as portable devices and laptops. It’s also widely used for industrial robots and power tools that require high capacity and power.

A secondary battery consists of cathode materials that determine the average voltage and capacity of a battery, and anode materials which induce current flow by storing then releasing lithium-iron from the cathode, via external circuits.

POSCO CHEMICAL, POSCO Group’s up-and-coming-global enterprise, produces key materials for secondary batteries – cathode and anode materials. The newly established POSCO CHEMICAL is the result of the merger back in April – between POSCO ESM, top-quality cathode producing enterprise, and POSCO CHEMTECH, Korea’s only natural graphite anode producer. As a result of their merge, POSCO CHEMTECH is expected to bring synergies between anode and cathode production. Large-scale early investments in production facilities are currently underway.

⑤ Battery Charge Stations? POSCO ICT Is on It

The biggest concern for the early adopters of EVs is the business of charging the EVs. Making the charge as easy as possible is the key part of the solution.

That’s where POSCO ICT comes in. POSCO ICT established ‘ChargEV,’ a charging infrastructure for EVs. ChargEV provides comprehensive services related to charging EVs, which includes charge stations, control systems, charging membership as well as car-sharing services. Considering accessibility and charging time, POSCO ICT has already established public charging networks at major hubs across Korea – Lotte Mart, E-Mart, Homeplus, and LG Electronics’ BEST SHOP, etc.

⑥ Safe Power Supply, With POSCO ENERGY

Providing power for EVs is also POSCO Group’s utmost priority. Since launching the energy business in 1969, POSCO ENERGY has steadily supplied power to the Seoul Metropolitan area for over 50 years. Through expanded businesses such as the LNG combined-cycle power plant in Incheon, the company went from being Korea’s first private power plant to Korea’s largest.

As it turns out, the world’s top steelmaker POSCO was also a key player in producing core EV materials. The next installation of [Find the Hidden POSCO] will explore POSCO technologies that can be found inside our homes.

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

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

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

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

<Material Production GHG Emissions for Common Body Structure>

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

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

l Five Different Vehicles, Single Result

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

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

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

<Comparative Life Cycle GHG Emissions>

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

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

l Aluminum: Light but Heavy

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

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

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

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

l AHSS Lowers GHGs by 12 Million Tons

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

<GHG Emissions of Lightweighting Six Million Vehicles>

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

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

Other equivalents for 12 million tons of  greenhouse gas include:

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

<Equivalents for 12 Million Tons of GHG>

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

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

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

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

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

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

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

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

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

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

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

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

l Global Automakers, All Eyes on AHSS

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

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

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

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

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

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

▲2019 Jeep Cherokee (Source: Detroit Auto Show)

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

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

l Giga Steel, Light but Strong

Source: Detroit Auto Show

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

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

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

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

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

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

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

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

Hyperloop floating through the Megacity has become the hallmark of future transportation. (Source: Big Think Edge)

The premise scene of the current Sci-Fi hit series, “Westworld” reveals guests being whisked to the entrance of Westworld, the show’s elaborate theme park. This is carried out in a super-fast magnetic levitation pod, whooshed forward in a blur at the speed of sound. This is in fact, the synthetic cameo of Elon Musk’s actual innovation, the Hyperloop.

Although this backdrop is 2052, evidently far-fetched to the eye, the advent of Hyperloop as we know it is even more materialized in reality than viewers may imagine. This mode of transport is a peek at the bird’s eye view of what’s to come.

The electric vehicle is a major mode of futuristic transportation we are already familiar with. The commercialization of flying cars and drone taxis as well are in the cards. And what is the role of steel in their manifestations?

The Era of Electric SUV with Lightweight Steel

The I.D. Crozz by Volkswagen is an electric-powered cross-over between a coupé and SUV (Source: Volkswagen Newsroom)

The transport of tomorrow we are most accustomed to is the electric car. Some of the major auto industry players such as BMW Group, Volkswagen Group, and Ford Group have formed a Pan-European EV charging network, Ionity to ensure enough charging stations to meet the growing EV units.

Frontrunner Tesla’s most recent electric SUV invention, the Tesla Model X has motivated global competitors to spring up a range of electric SUVs. With the release of Jaguar I-Pace in March and the Hyundai Kona Electric in May along with the anticipated launch of Audi’s E-tron Quattro and Sportback, worldwide carmakers and consumers alike are aware that a new generation of electric SUV and its crossover versions are already in full swing.

Previously, the electric motor was commonly applicable only in compact or subcompact cars due to its limited battery capacity. They weren’t capable of reaching over a certain distance even once fully charged. As follows, lightweighting is inevitable to secure more miles on the road.

The development of battery performance and vehicle lightweighting technologies have enabled the creation of the electric SUV. Primary components of EV are the electric motors and batteries, especially the lithium-ion batteries that power the vehicle using POSCO’s cathode and anode.

An anode is a positively charged electrode in which the current flows into the system. Since last year, POSCO ES MATERIALS has been manufacturing highly-stable anode material, the PG-NCM which is world’s finest in quality. The cathode generates electricity by storing and releasing the lithium contained in the anode. At present, POSCO CHEMTECH is the sole manufacturer of anode materials in the domestic market.

The second solution to car lightweighting for more mileage would be POSCO’s Giga Steel. Giga Steel is a high-intensity steel capable of enduring the weight of 1,500 subcompact cars with a size that is merely 4 inches in width and 6 inches in length. Its intensity is thrice that of an automotive aluminum enabling even thin steel sheets to perform as robust car structure. Accordingly, it is unmatched in resolving both lightweight and stability issues for its lightness and high endurance. Experts predict the increase in demand for ultra-high tensile steel with gigapascal capacity of endurance suitable for advanced safety measures.

Whizzing from New York to Washington DC in 30 Minutes

Hyperloop travels at a supersonic speed of 760 miles per hour faster than that of a commercial airplane. (Source: Inverse)

A quick weekday evening spent with a family member in a US home state after work may just happen. A San Francisco resident can enjoy dinner after work with a friend from college in downtown LA in just 30 minutes. The same amount of time would take for a Dutch in Amsterdam to travel to Paris for a quick photo of the Eiffel Tower. The mode of transportation? None other than the Hyperloop.

It is one of the most innovative technologies in the next generation of transport initially mentioned in 2012 and explicitly open-sourced the following year by the CEO of Tesla Motors and Space X, Elon Musk. A pressurized pod would float through the vacuum tunnel while magnetic levitation enables it to hover above the rail to reduce friction.

Theory suggests the speed of Hyperloop is around 760 mph, considerably faster than that of a regular passenger flight which is 547 to 575 mph. It can transport passengers to neighboring states in the US or to neighboring countries in about half an hour. There is almost zero emission while solving congestion problems in a sustainable and cost-efficient way.

Since its conception, high-tech companies have been chasing after the hyperloop reality around the world. This includes Elon Musk’s Boring Company, business magnate, Richard Branson’s Virgin Hyperloop One, and LA-based Hyperloop Transportation Technologies (HTT), an American research company.

HTT has been constructing one of two test tracks in France, ready to convey the first passenger capsule later this year. It had already signed a 150 km Hyperloop system between Abu Dhabi and Dubai, partly expected to be operational in 2020. This agreement is the foundation to eventually run Hyperloop in between the Emirates and Saudi Arabia. Richard Branson announced earlier this year that he had signed an agreement with India’s Maharashtra State government to build Virgin Hyperloop One connecting the distance reaching up to 150 kilometers between two cities, Mumbai and Pune. We may eventually reap the benefits of the Hyperloop bringing the world closer together.

Most Hyperloop companies are developing tubes or tunnels out of steel from which most of the air has been removed. POSCO is also researching the application of steel designed for the Hyperloop while at its refurbished “Steel Gallery” exhibit at POSCO Center, visitors can experience Hyperloop through an interactive wall to learn about the anticipated performances of steel in the near future.

Beating Ground Traffic on a Drone Taxi

CityAirbus’s Drone Taxi underway (Source: Helicopter Newswire)

The opening scene of “Blade Runner 2049” released in October last year features a flying car whirring across the sky. The Passenger, Blade Runner “K” played by Ryan Gosling wakes up from what is a self-driving vehicle, flying him across his journeys. This premise of flying cars is always that one thing common in Sci-Fi movies, even the older version of Blade Runner which hit theaters back in 1982.

Considering its advantages versus overpopulation and hours idling in traffic, this may come away from the silver screen and into our real lives. No less than 19 companies have pursued the competition in commercializing flying cars.

Last May, Uber has teamed up with NASA, announcing its plans to service aerial taxi services by 2023 in LA, Dallas, and Dubai. Uber has signed an agreement with NASA to plan a new air traffic control software for what could be the beginning of establishing a new aerial smart system enabling advanced and efficient infrastructure from up above. Its’ servicing demonstration video reveals the passenger booking her flight through Uber app. Uber has already invested €20 million in flying taxi service in Paris, France. Its high-profile competitor, the Kitty Hawk project backed by Google founder, Larry Page has released its own version of the flying vehicle commercially available for sale.

Other countries such as Dubai and Japan have adopted their own versions of drone taxi services and is expediting its completion and starting launch by 2020. The Japanese government has partnered up with companies such as Boeing, Airbus, and Japanese Airlines and hopes to launch its prototype to be used to light the Olympic flame during the Games hosted by Tokyo in 2020.

Cars with wings especially require utmost safety and lightweighting even more so than most ground-based cars. POSCO’s ultra-high intensity steel sheet produced with advanced Giga Steel will be unequaled in offering such breakthrough technology.

These examined future transportations require steel as its fundamental material. Steel in itself faces constant evolution, not unlike the advancement of transportation as it is unique for both its strength and lightweight. Keeping its endless possibilities in mind, steel’s significance will be proven further in the newer forms of transportation to come.

The U.S. is headed towards a major shortage of truck drivers. (Source: The New York Times)

However, the U.S. is short of about 30,000 to 35,000 drivers for every 750,000 trucks, and the number of driver shortages may reach up to 245,000 by 2022. That’s because right now, the average age of truck drivers in the U.S. is 55, and potential new recruits are choosing to sign up for construction or manufacturing jobs instead.

All this leads to climbing prices for freight transportation. Last December, at the peak of holiday deliveries, U.S. companies saw the highest monthly average rate for freight transportation since 2010. The high operation costs and lower profit margins are putting a heavy strain on industries. Heading into 2018, companies have to compete for carriers as there is just one truck available for every 12 loads.

As a result, Major automakers are heavily invested in autonomous electric freight trucks such as Tesla, Volvo and Daimler, and there are many proponents of an eco-friendly, safe and driverless future for freight transportation. However, autonomous freight trucks are not a realistic option for companies just yet. At a time of transition between the old and the new, there is a serious lack of capacity in freight transportation, and companies are left to deal with the higher costs for delivery.  

But good news right around the corner

Although the driver shortage is a major concern, it is a natural phenomenon in the transition towards a safer, more sustainable and more efficient freight transportation industry.

Uber’s autonomous freight trucks are in operation with a human safety driver on the highways of Arizona. (Source: Future Car)

Already, Uber has its autonomous trucks on the highways of Arizona. Every truck does have a human driver present to take over anytime, and the company uses transfer hubs to transfer goods between highways and local roads. Autonomous trucks are the safest and most efficient for use on highways, so human drivers transport goods from highways to the final destination. The company is working to operate without human backup drivers in the near future.

Waymo’s autonomous freight trucks have gone through almost a decade of testing and is now delivering supplies for Google in Atlanta. (Source: Wired)

Waymo is another company with autonomous trucks already in operation. Just this month, the company’s autonomous freight trucks started transferring equipment for Google data centers in Atlanta.

Embark was the first company to complete a successful coast to coast run with an autonomous truck. (Source: Micro Power Grids)

Embark also has its autonomous trucks in operation. Earlier this year, the company made a successful 2,400-mile trip from California to Florida with a human safety driver on board. The company has plans to commercialize its services in the coming years.

SEE ALSO: 6 Cities On the Road to a Driverless Future

Speeding up delivery

Numerous other automotive and tech companies besides those mentioned above are getting ready for autonomous freight transportation. The faster autonomous freight trucks are able to operate commercially, the faster industries can cut costs, improve delivery times and reduce their carbon footprint.

This means software technology, high-capacity batteries as well as the right automotive materials will play a crucial role in the future of the freight transportation industry, as well as in related industries. This transformation will open up new business opportunities for automakers, software companies as well as steel manufacturers like POSCO.

For autonomous truck manufacturers looking for ultra-lightweight yet super strong materials for optimal fuel efficiency, POSCO developed POSCO GIGA STEEL. The advanced high-strength steel (AHSS) material is 3 times stronger and 3.5 times cheaper than aluminum. Steel is also 100 percent recyclable and an electric vehicle made of AHSS requires 30 percent less energy than aluminum throughout its entire lifecycle. POSCO also developed a premium non-oriented electrical steel called Hyper NO for the most advanced and sustainable electric motors.

SEE ALSO: Why Electrical Steel Can Make All The Difference In EV Motors

POSCO also works with its auto partners to research and provide customized technology and materials solutions for their autonomous EVs. In the midst of a critical shortage of truck drivers, POSCO hopes to speed up autonomous EV adoption both for personal and commercial transportation and aid the transition into a more efficient and environmentally sustainable economy.

Cover photo courtesy of Time.

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.

Scientists predict 2018 may be a tumultuous year for earthquakes. (Source: Take Two)

As structural damage is the leading cause of injury and deaths during an earthquake, architects, engineers and builders need to make sure buildings are built with the right materials and design.  

SEE ALSO: What it Takes to Build a Natural-Disaster-Proof House

The Materials

The most dangerous type of earthquakes are ones that trigger horizontal movements, because tall buildings are better at resisting vertical loads than horizontal ones. These ground motions can damage building foundations in a matter of minutes, causing severe injuries and deaths. Building a structure to withstand seismic waves starts with the right materials with the right properties, and steel is by far the most widely used material for building earthquake-resistant buildings.

According to the World Steel Association, ductile buildings are safer as they dissipate energy from seismic waves. A building will typically have ductile parts that can undergo plastic deformations without complete structural failure during an earthquake. Steel is the most common type of material for such parts.

Moreover, due to the law of inertia, the lighter the building, the less force seismic waves will exert on the building. That’s why it’s important, especially for taller buildings, to be made of light and flexible materials such as steel that can “bend” with the movement of earthquakes. On average, multi-story steel buildings are 60 to 70 percent lighter and 10 times stronger than concrete-framed buildings of the same size.

The Design

With steel, builders can add vital designs and reinforcements to keep the structure standing through an earthquake. Here’s some of the most widely-used measures.

Cross braces transfer the force of an earthquake to the ground. (Source: Earthquakes in India)

The structural integrity of buildings can be reinforced with steel cross braces that frame the exterior of a building in an x-shape. Ultimately cross braces can transfer the force of seismic waves back down to the ground, instead of letting the building take the hit. Builders can also reinforce the walls of buildings with additional vertical walls, or shear walls, that add stiffness to the frame of the building, allowing it to resist swaying or horizontal movements.

Base isolators absorb much of the shock of seismic waves. (Source: Embelton)

Base isolation involves separating the building from the foundation so that the isolators to absorb shock from the earthquake. The isolators allow the building to move at a slower pace because they dissolve a large part of the shock. Moment-resisting frames also effectively dissipate energy from floors and roofs to the building’s foundation and the stiff yet flexible frames can change shape during an earthquake. Although more costly, moment-resisting frames enable buildings to withstand an earthquake with excessive horizontal movement.

Putting it into practice with POSCO’s Steel House

In September 2017, Young Bae Kim’s home in Gyeongju province, Korea was hit with a 5.8 magnitude earthquake, just 8.9 km from where the earthquake started. Surprisingly, Kim’s home was unscathed. “I could feel the ground shake, but the house was completely under control.” Kim expressed.

Kim lives in one of the Steel Houses built by POSCO employees who volunteer to build homes and bridges for communities in need. Each Steel House is made with POSCO’s lightweight structural steel known for its durability, fire resistance and vibration resistance. The homes also incorporate PosMAC, a specialized galvanized steel that is 5 to 10 times more corrosion-resistant than standard steel and is more durable and affordable.

POSCO Employees volunteer their time to build steel houses in rural communities.

Because all the Steel Houses survived the Gyeongju earthquake while other homes were damaged, more and more people in Korea are choosing steel for their homes over traditional building materials such as wood and concrete. The same trend can be observed in Japan, where earthquakes are much more frequent. In order to build more earthquake-resistant buildings, steel is still the best solution available.

Cover photo courtesy of CNN.

However, these building projects are on another level of huge, and with all the megacities popping up throughout the country, China boasts many of the biggest infrastructure projects in the world. Here’s the Steel Wire’s look at some of the most impressive to date.

Three Gorges Dam

China is home to the largest dam in the world, measuring 1.5 miles in length and sitting 60 (!) stories tall. The Three Gorges Dam took 1.92 million tons of rolled steel to complete, along with 10.82 million tons of cement and 1.6 million cubic meters of timber. The dam opened in 2003 on the Yangtze River and last year, generated a record-high 97.8 billion kilowatt-hours of electricity, 4.35 percent higher than the previous year.

The Three Gorges Dam is the biggest dam in the world and is made up of 1.92 million tons of steel. (Source: Wikipedia)

Beijing Capital International Airport

Beijing Capital International Airport (PEK) was the second largest and busiest airport in the world in 2016, just behind the Hartsfield–Jackson Atlanta International Airport in the U.S. PEK recorded 94,393,454 passengers that flew in and out in 2016, a 5 percent increase from 2015, and is easily the biggest airport in all of Asia.

Beijing Capital International Airport is the biggest airport in Asia, and second in the world. (Source: Top China Travel)

The first phase of the airport cost USD 3.5 billion and was completed in 2008, but in order to handle the growing number of passengers, an expansion project is planned for 2025. The estimated 5-year project will almost double PEK’s capacity and cost an additional USD 13 billion.   

Jiaozhou Bay Bridge

China is also home to the longest sea-crossing bridge in the world. The massive structure stretches over 26.4 miles and connects the cities of Qingdao and Huangdao. The 110ft width accommodates 6 traffic lanes that are supported by 5200 steel pillars.

The Jiaozhou Bay Bridge is held up by 5200 steel pillars. (Source: Feel the Planet)

The bridge first opened in 2011 and took USD 2.3 billion and over 10,000 workers to build. The Jiaozhou Bay Bridge also took 450,000 tons of steel to complete, allowing the bridge to be able to withstand earthquakes up to 8.0 in magnitude, typhoons and the force from a 300,000-ton object.  

Jiuquan Wind Power Base

Not surprisingly, the largest wind farm in the world located in China. Jiuquan Wind Power Base is made up of 7,000 turbines that generate enough electricity to sustain a small country. The plant was approved in 2008, and the government has pledged an additional USD 17.4 billion by 2020 as part of the effort to develop China’s renewable energy industry. For now, only 3.3 percent of all the electricity generated in China comes from wind turbines. With the additional investment, Jiuquan Wind Power Base will be able to generate a massive 20 gigawatts of sustainable electricity.

The Jiuquan Wind Power Base generates enough energy to power a small nation. (Source: The New York Times)

New Century Global Center

What does the biggest building in the world look like? A mini country. Located in Chengdu, Sichuan province, the New Century Global Center combines a shopping mall, water park, hotels, movie theaters, offices, restaurants, ice rink and more into 19 million sq.ft. of space. The structure is made of glass and steel and measures 500 meters long, 400 meters wide and 100 meters high. Designed by architect Zaha Hadid, it even has artificial sun for the perfect weather, 24 hours a day.

The New Century Global Center located in Chengdu is the largest city in the world. (Source: Thousand Wonders)

Port of Shanghai

The world’s biggest ports are mostly located in China, and the biggest one is the Port of Shanghai. In 2012, 744 million tonnes of cargo and 32.5 million twenty-foot equivalent units (TEUs) of steel containers passed through the port. The entire area of the port on the Yangtze River covers 3,619km² comprised of 3 main ports: Wusongkou, Waigaoqiao and Yangshan Deep-Water Port. About 25 percent of China’s trade passes through the Port of Shanghai, or 2,000 steel container ships per month.

The Port of Shanghai is the largest port in the world and a quarter of China’s trade passes through it. (Source: Thomson Reuters)

Most recently, the 4th phase of the Yangshan Deep-Water Port was completed, making it the largest automated port in the world. It spans across 2.23 million square meters, and can automatically handle 4 million standard containers per year, or 25 per hour. It was also built to accommodate the heaviest ships in the world.

China is using its steel to build up the country’s infrastructure, and set world records along the way. Besides being impressive in size, the structures are expected to contribute to greater connectivity and economic prosperity throughout China.

Cover photo courtesy of Morgan Stanley.