future steel vehicle advanced powertrains and the .../media/files/autosteel/great designs in...

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Harry Singh (EDAG FSV Program Manager)

Future Steel Vehicle and the influence on Material Selection

Great Designs in Steel: May 13


Harry Singh

Future Steel Vehicle – Advanced Powertrains

and the influence on Material Selection

Great Designs in Steel: May 13th 2009

1. Introduction:

EDAG – brief overviewWorldAutoSteel, Sponsoring Companies

2. WorldAutoSteel – Future Steel Vehicle (FSV)

• Advanced Power Train Systems HEV, PHEV, BEV, FCEV


• Advanced Power Train Systems HEV, PHEV, BEV, FCEV

• Well to Wheels efficiencies

• FSV Materials Portfolio

WorldAutoSteel, Sponsoring Companies

Future Steel Vehicle (FSV)

Advanced Power Train Systems HEV, PHEV, BEV, FCEV

Overview


Advanced Power Train Systems HEV, PHEV, BEV, FCEV

Well to Wheels efficiencies

FSV Materials Portfolio


Product Development Engineering Services

� Styling

� Design & Engineering

� Computer Simulation

In USA since 1994, 350 employees

EDAG - Overview


Product Development Engineering Services

In USA since 1994, 350 employees

WorldAutoSteel, the automotive group of the World Steel Association, continually

explores steel innovation that demonstrates the value of steel to the automotive

industry.

WorldAutoSteel member companies from around the world pool global resources to

deliver vital research that is central to effective steel automobile applications.

ArcelorMittal - Luxembourg

Baoshan Iron & Steel Co. Ltd. - China


Baoshan Iron & Steel Co. Ltd. - China

China Steel Corporation - Taiwan, China

Hyundai-Steel Company - South Korea

JFE Steel Corporation - Japan

Kobe Steel, Ltd. - Japan

Nippon Steel Corporation - Japan

Nucor Corporation - USA

WorldAutoSteel, the automotive group of the World Steel Association, continually

explores steel innovation that demonstrates the value of steel to the automotive

WorldAutoSteel member companies from around the world pool global resources to

deliver vital research that is central to effective steel automobile applications.

WorldAutoSteel Members

POSCO - South Korea

Severstal - Russia/USA


Severstal - Russia/USA

Sumitomo Metal Industries, Ltd. - Japan

Tata Steel & Corus - India, UK, Netherlands

ThyssenKrupp Stahl AG - Germany

United States Steel Corporation - USA

Usinas Siderurgicas de Minas Gerais S.A. -

Brazil

Voestalpine Stahl GmbH - Austria

WorldAutoSteel continues to lead the materials revolution through

projects like the Ultra Light Steel Family of Research:

• ULSAB, ULSAC, ULSAS (BIW, Closures & Suspensions)

• ULSAB-AVC (Advanced Vehicle Concepts)

WorldAutoSteel’s newest program Future Steel Vehicle (FSV)



Part 1 – Engineering Study (2008 –

Part 2 – Concept Design (July 2009 -

Part 3 – Demonstration Hardware (2010

WorldAutoSteel continues to lead the materials revolution through

projects like the Ultra Light Steel Family of Research:

ULSAB, ULSAC, ULSAS (BIW, Closures & Suspensions)

AVC (Advanced Vehicle Concepts)

Future Steel Vehicle




– July 2009)

- 2010)

Demonstration Hardware (2010 - 2011)

FSV Objective:

Strengthen Steel’s Position as the Automotive Structural Material of Choice for the

Future Vehicles (2020) & identification of new applications for steel.

FSV Justification:

Global growth of vehicle fleet from 820,000,000 vehicles in

2008 to 1 billion by 2020.

Transportation at present is 96% dependence on petroleum.



Daily worldwide petroleum usage 85,000,000 barrels

Vehicle emissions standards: EU 130 CO2 g/km 2009 & 95

g/km 2020, Japan 145 g/km 2009, USA CAFE 35mpg 2015.

Increasing vehicle efficiencies to reduce petroleum

consumption & to reduce Green House Gas emissions:

are the key drivers for the implementation of Advanced

Powertrains with increased focus on Vehicle Mass Reduction

Strengthen Steel’s Position as the Automotive Structural Material of Choice for the

Future Vehicles (2020) & identification of new applications for steel.


Global growth of vehicle fleet from 820,000,000 vehicles in

Transportation at present is 96% dependence on petroleum. COCOCOCO2222



worldwide petroleum usage 85,000,000 barrels

EU 130 CO2 g/km 2009 & 95

g/km 2020, Japan 145 g/km 2009, USA CAFE 35mpg 2015.

Increasing vehicle efficiencies to reduce petroleum

consumption & to reduce Green House Gas emissions:

are the key drivers for the implementation of Advanced

Vehicle Mass Reduction.

COCOCOCO2222

FSV: Phase 1


FSV: Phase 1 – Engineering Study


The assessment of the announcements from automobile manufacturers show progress on various technologies which include;

1. Conventional internal combustion engine (ICE) based smaller more efficient gasoline/diesel vehicles

2. Higher efficiency Hybrid Electric Vehicle (HEV)


3. Plug-in hybrids (PHEV) with limited range of miles driven in Electric Mode. This option offer significant reduction in fossil based petroleum usage, especially when the daily distances driven are close to the vehicle’s electric range. The additional distance being driven using petroleum or Bio

4. Battery Electric Vehicles (BEV) with driving range of approximately 200 km

5. Fuel Cell Electric Vehicles (FCEV) using hydrogen gas as a fuel source

The assessment of the announcements from automobile manufacturers show progress on various technologies which include;

Conventional internal combustion engine (ICE) based smaller more

Higher efficiency Hybrid Electric Vehicle (HEV)

FSV - OEM Direction/Trends


in hybrids (PHEV) with limited range of miles driven in Electric Mode. This option offer significant reduction in fossil based petroleum usage, especially when the daily distances driven are close to the vehicle’s electric

The additional distance being driven using petroleum or Bio-fuels

Battery Electric Vehicles (BEV) with driving range of approximately 200 km

5. Fuel Cell Electric Vehicles (FCEV) using hydrogen gas as a fuel source

A broad range of alternate propulsion vehicles have been announced by automakers

around the world. The following table shows the number of vehicles announced by

OEMs (Concept and Production)

Electric only Plug-in Hybrid

BEV 18

PHEV -

OEM Announcements

Futu

re S

teel

Vehic

les

Type


PHEV -

FCEV -Futu

re S

teel

Vehic

les

Mitsubishi (2009) Subaru (C) Mercedes (2011) Th!nk (2009)BMW (2015) Tesla (2009) BMW (2009) Nissan (2010) NICE (2009) Dodge (2010)Toyota (2012) REVA (C)BYD(2011) TATA (2011)Ford (2011) Magna (C)

FSV - OEM Announcements

A broad range of alternate propulsion vehicles have been announced by automakers

around the world. The following table shows the number of vehicles announced by

Plug-in Hybrid Fuel Cell

- -

9 -

OEM Announcements


9 -

- 4

Honda (2009)GM (C)Hyundai (C)Mercedes (C)

GM (2011) GM (2010)Fisker (2010)Chrysler (2012)Toyota (2010) Mercedes (2012)BYD (2009)Volvo (C)

(XXXX) – Proposed year of production

(c) – Concept Vehicle

F

PHEV (Plug-in Hybrid Electric Vehicle) Toyota – Prius PHEV


BEV (Battery Electric Vehicle) Mitsubishi - I MiEV

Future Advanced Powertrains

EREV (Extended Range Electric Vehicle) GM - VOLT


GM - VOLT

FCEV (Fuel Cell Electric Vehicle) Fuel Compressed Hydrogen Gas Honda - Clarity


Daimler Smart for-two 2695 mm

TATA nano 3100mm – 4 Occupants

Small Cars can be affordable, safe & fun, and HEV & BEV’s


TATA nano 3100mm – 4 Occupants

Toyota IQ 2985mm – 3+ Occupants

70


70

FSV – Fuel Cell Technology Assessment


kWh/kg


FSV – BEV Battery Technology Assessment


Petroleum to Li


Approx 110 Wh (90 Wh for small car) of energy required per km of driving

For small car 5 kWh battery driving range 32 km (year 2015 cost estimate $2,346)

For mid-size car 12 kWh battery driving range 64 km (year 2015 cost estimate $5,400)

Petroleum to Li-ion Batteries?


Approx 110 Wh (90 Wh for small car) of energy required per km of driving

For small car 5 kWh battery driving range 32 km (year 2015 cost estimate $2,346)

size car 12 kWh battery driving range 64 km (year 2015 cost estimate $5,400)

USA


PHEV40 – 70% daily miles driven in Electric mode

Miles

Europe

PHEV20 – 50% daily miles driven in Electric mode

Vehicle Daily Distances Traveled


km

FSV 1

PHEV20

Electric Range – 32kmTotal Range – 500km

Max Speed -150km/h

0-100 km/h 11-13 s

Worldwide over 70% market share between two vehicle sizes: Small car

(up to 4,000mm, A/B class) and Mid


FSV 2

PHEV40

Electric Range – 64kmTotal Range – 500km

Max Speed -161km/h

0-100 km/h 10-12 s

Range based on UDDS cycle

FSV: Vehicle Size & Power Trains

20

32km500km

150km/h

13 s

BEV

Total Range – 250km

Max Speed -150km/h

0-100 km/h 11-13 s

Worldwide over 70% market share between two vehicle sizes: Small car

(up to 4,000mm, A/B class) and Mid-Class car (up to 4,900mm, C/D class)


0-100 km/h 11-13 s

40

64km500km

161km/h

12 s

FCEVTotal Range– 500km

Max Speed -161km/h

0-100 km/h 10-12 s

Range based on UDDS cycle

FS

Occupants:

Front Row Seating – 2

Rear Row Seating – 2+


Vehicle Class Average Front Leg Room

A 1055

B 1065

C 1070

D 1075

1065 mm

FSV1: Occupants, Front & Rear Leg Room and Luggage Targets

825 mm


Average Front Leg Average Rear Leg Room

760

850

877

961

Luggage Liters

170

340

370

450

250 Liters

FS

Occupants:

Front Row Seating – 2

Rear Row Seating – 3


Vehicle Class Average Front Leg Room

A 1055

B 1065

C 1070

D 1075

1065 mm

FSV2: Occupants, Front & Rear Leg Room and Luggage Targets

920 mm


Average Front Leg Average Rear Leg Room

760

850

877

961

Luggage Liters

170

340

370

450

370 Liters

FSV:


V: Advanced Powertrains Concept Layouts

FSV: BEV Battery Electric Vehicle


Vehicle

FSV: FCEV Fuel Cell Electric Vehicle

FSV: PHEV40

Plug-in Hybrid Electric Vehicle


At present vehicle use (Pump to Wheel) Fuel consumption:

km/l or CO2 g/km or mpg

FSV: Total Life Cycle Assessment (LCA)


1. Green House Gas CO2: g/km

2. Energy Efficiency: wh/km

3. Cost of Ownership: $/km

LCA: For Vehicle life of 200,000 km

FSV

Well to Pump

Internal Combustion Engine100

80

84

Gasoline Production

Bio Fuel:

Ethanol

Diesel

Diesel Production

38

31


Engine100 units of energy

38Electricity Generation US-Mix

H2 - NG Reformation 62

Greet 1.8b Argonne National Lab

91.5Renewable

Electric Motor Drive

FCEV

SV: Efficiency of Fuels and Energy Sources

16

21

8

8

Diesel 25-40 % efficient

Bio-Diesel 25-40 % efficient

Gasoline 20-35 % efficient

Ethanol 22-37 % efficient

Combustion

Pump to Wheel Well to Wheel


8Bio-Diesel 25-40 % efficient

20

7031

9

21

27 24 10

35 33

57 23

Motor DriveBEV

FCEV

FSV1

3

4

5

6

7

Gasoline

PHEV20 - CS

PHEV20 - 65km

PHEV20 - 150km

PHEV20 - 500km


CD – charge depleting – energy from battery CS – charge sustaining – energy from petroleum, similar to HEV

0.0 20.0 40.0 60.0 80.0

1

2

CO2 Emissions in g/km

PHEV20 32km CD

BEV

0

0

FSV1 - Pump to Wheel CO2 Emission g/km

Pump to Wheel

100 kg Vehicle Mass Reduction

130 g/km 2012 EU

34 mpg, 14.4 km/l, 7.0 l/100km

95 g/km 2020 EU

110

Toyota Prius 2010


energy from battery energy from petroleum, similar to HEV

80.0 100.0 120.0 140.0 160.0 180.0 200.0


140 g/km 2009 JAMA (voluntary)

USA - Electricity Production


Results also available for Europe, India, China, Japan, 100% coal, 100% Renewable

FSV: Electricity Production

Electricity Production


[Source: Greet 1.8b US-Mix]

Results also available for Europe, India, China, Japan, 100% coal, 100% Renewable

FSV1

2

3

4

5

6

7Gasoline

PHEV20 - CS

PHEV - 32km CD

PHEV20 - 65km

PHEV20 - 150km

PHEV20 - 500km

E50J57


-10.0 10.0 30.0 50.0 70.0 90.0

1

2


E50 Electricity Mix Europe

PHEV20 - 32km CD

BEV

E50J57

CD – charge depleting – energy from battery CS – charge sustaining – energy from petroleum, similar to HEV

0

FSV1 - Well to Wheel CO2 Emissions g/km

Well to Pump (US Mix Electricity)

Pump to Wheel


114

138

Toyota Prius 2010


110.0 130.0 150.0 170.0 190.0 210.0 230.0 250.0


J57 Electricity Mix Japan

114

Electricity 100% Coal110


FSV2

3

4

5

6

7

8Gasoline

PHEV40 - CS

PHEV40 64km CD

PHEV40-100km

PHEV40-250km

PHEV40-500km

0


0.0 20.0 40.0 60.0 80.0

1

2


CD – charge depleting – energy from battery CS – charge sustaining – energy from petroleum, similar to HEV H2 NG – Hydrogen from Natural Gas H

FCEV H2 - NG

FCEV H2 - Elec

0

0

FSV2 - Pump to Wheel CO2 Emission g/km

Pump to Wheel


130 g/km 2012 EU

29 mpg, 12.5 km/l, 8.0 l/100km

95 g/km 2020 EU

134

Ford Fusion HEV 2010


80.0 100.0 120.0 140.0 160.0 180.0 200.0



Hydrogen from Natural Gas H2 Elec – Hydrogen from H2O Electrolysis

140 g/km 2009 JAMA (voluntary)

FSV2

4

5

6

7

8Gasoline

PHEV40 - CS

PHEV40-100km

PHEV40-250km

PHEV40-500km


-10.0 10.0 30.0 50.0 70.0 90.0 110.0

1

2

3


FCEV H2 - Elec

FCEV H2 - NG

PHEV40 64km CD

CD – charge depleting – energy from battery CS – charge sustaining – energy from petroleum, similar to HEV H2 NG – Hydrogen from Natural Gas H2 Elec

FSV2 - Well to Wheel CO2 Emission g/km

Well to Pump (US Mix Electricity)

Pump to Wheel


168

Ford Fusion HEV 2010


110.0 130.0 150.0 170.0 190.0 210.0 230.0 250.0



Hydrogen from Natural Gas H2 Elec – Hydrogen from H2O Electrolysis

FS

●●●● Gasoline AT

●●●● Gasoline CVT

●●●● Gasoline MT

●●●● Hybrid

▲▲▲▲ Diesel

▲▲▲▲ LPG

CO

2

(g/k

m)

w w w . a u t o s t e e l . o r g27

Vehicle Mass (kg)PHEV, CD – Battery Charge Depleting

BEV – Electric Vehicle

FCEV – Fuel Cell Vehicle

PHEV20, CS – Battery

Charge Sustaining

FSV: Pump to Wheel CO2 g/km comparison

ICE

Hybrid


Vehicle Mass (kg) FSV – PHEV20 & PHEV40

70% Miles Driven in EV mode – Energy from Electric Grid

30% Miles Driven in HEV mode – Energy from Petroleum

PHEV40, CS – Battery

Charge Sustaining

Part 1 – Engineering Study (2008 – July 2009)

Part 2 – Concept Body Structure Design (July 2009



July 2009)

Concept Body Structure Design (July 2009 - 2010)




FSV: Phase 2

• Investigate the vehicles mass reduction potential with the use of Advanced High Strength Steel (AHSS), advanced manufacturing technologies and use of computer aided structural optimization.

• Understand the loads imposed by advanced powertrains on the vehicle structure and hence identify requirements for new grades of steel for optimized low mass vehicle structural applications and designs.


designs.

FSV: Phase 2 – Concept Design

Investigate the vehicles mass reduction potential with the use of Advanced High Strength Steel (AHSS), advanced manufacturing technologies and use of computer aided structural optimization.

Understand the loads imposed by advanced powertrains on the vehicle structure and hence identify requirements for new grades of steel for optimized low mass vehicle structural applications and


BIW Wt. vs. GVW

300

350

400

450

BIW

(K

g)

'01 - '03 Steel BIWULSAB-AVC

Aluminum BIW'04 - '08 Steel BIW

Top 10 Steel BIWEU Super Light CarLinear ('01 - '03 Steel BIW)


150

200

250

300

1000 1500

GVW (Kg)

BIW

(K

g)

BIW Wt. vs. GVW

FSV – Body Structure Mass Targets


2000 2500 3000

GVW (Kg)


• Battery Electric

• Plug-in HEV

• Fuel Cell

Low StrengthSteels (<210MPa)

Ultra High Strength Steels (>550MPa)

High Strength Steels

Elo

ng

ati

on

(%

)

30

40

50

60

70

Mild

BHBH


Elo

ng

ati

on

(%

)

Tensile Strength (MPa)

0

10

20

0 600 1200300 900

MART

ULSAB Program: Achieved 25% reduction in BIW Mass


Steel Grades for ULSAB (2000)


1200 1600

MART

ULSAB Program: Achieved 25% reduction in BIW Mass




Elo

ng

ati

on

(%

)

30

40

50

60

70

Mild

BHBH

Steel Grades for ULSAB


Elo

ng

ati

on

(%

)


0

10

20

0 600 1200300 900

MART

ULSAB – ABC Program: Achieved 24% reduction in BIW Mass


Steel Grades for ULSAB – AVC (2004)


1200 1600

MART



Elo

ng

ati

on

(%

)

30

40

50

60

70

Mild

Steel


Elo

ng

ati

on

(%

)


0

10

20

30

0 600300

BHBH


el Grades Availability for FSV (2020)



1200900 1600

MART

FSVChoice of Steel

Grades

Steel


el Grades Availability for FSV (2020)


Manu

Manufacturing Techniques considered for the WorlAutoSteel ULSAB & ULSAB-AVC programs.


nufacturing Processes ULSAB

Manufacturing Techniques considered for the WorlAutoSteel ULSAB &


Manufacturing Techniques available (existing and emerging) that are being considered for the WorlAutoSteel FSV program.

M


Manufacturing Techniques available (existing and emerging) that are being considered for the WorlAutoSteel FSV program.

Manufacturing Processes FSV


WorldAutoSteel – Future Steel Vehicle (FSV)

• Advanced Power Train Systems PHEV

• Well to Wheels efficiencies

• FSV Materials portfolio


Part 1 – Engineering Study (2008

Part 2 – Concept Body Structure Design (July 2009


Future Steel Vehicle (FSV)

Advanced Power Train Systems PHEV20, PHEV40, BEV, FCEV

Well to Wheels efficiencies

Summary


Engineering Study (2008 – July 2009)

Concept Body Structure Design (July 2009 - 2010)



FSV – Body Structure Mass Targets


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