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ULSAB-AVC – on the Road Today

Jody ShawAutomotive Center

United States Steel Corporation


At GDIS 2002 we introduced ULSAB-AVC

74%

2%

10%4%1% 4%

1%4%

Dual Phase TRIP Mart ensit e Complex Phase Bake Hardenable High St rengt h IF HSLA Ot her

ULSAB-AVC• 25% Mass Reduction • Improved Crash Performance• At No Additional Cost

In 2002 the steel industry introduced ULSAB-AVC with significant claims of improvement performance with AHSS


What have we done since then?E

long

atio

n (%

)

Yield Strength (MPa)

0

10

20

30

40

50

60

70

0 400 600 1000200 800 1200

IF

MildIF

HSLADP, CP

TRIPBHCMn

IS

MART

Steel Grade Development

Since then the steel industry has been developing the grades needed to meet the promise


Partnerships & Collaboration

What have we done since then?

We have been working though partnerships with directly with our customers to address the design and manufacturing challenges.


What have we done since then?

Volvo XC90

Ford 500

Ford Mustang

Chevy MalibuJeep Cherokee

Honda Civic

BMW3 Series

GM Solstice

Porsche Cayenne

BMW X6

Vehicle ManufacturerProduct Development

Vehicle manufacturers have been incorporating these concepts into their products and we have seen the progress over the years at each GDIS event.


So how far have we come?

74%

2%

10%4%1% 4%

1%4%

Dual Phase TRIP Mart ensit e Complex Phase Bake Hardenable High St rengt h IF HSLA Ot her

ULSAB-AVC• 25% Mass Reduction • Improved Crash Performance• At No Additional Cost

Has ULSAB-AVC been realizedin a production vehicle?

But have we been able to deliver on our promise?


Has ULSAB-AVC been realized?

Basis of the Assessment

European Vehicle Data BaseTo answer this question – two data sets are utilized. The A/SP mass compounding study proposes a clear

relationship between BIW mass and GVW as a means of normalizing the BIW comparisons and the a2mac1 benchmarking data provides a look at this metric for 100+ European vehicles.



The plot shows the typical performance of BIW at the time of ULSAB-AVC launch and confirms and even exceeds the magnitude of the 25% mass saving claim.

BIW Wt. vs. GVW

150

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1000 1500 2000 2500 3000GVW (Kg)

BIW

(Kg)

'01 - '03 Steel BIWULSAB-AVC

27% Lighter than typical 2001 – 2003 BIW



BIW Wt. vs. GVW

150

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250

300

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450

1000 1500 2000 2500 3000GVW (Kg)

BIW

(Kg)

'01 - '03 Steel BIWULSAB-AVCAluminum BIW

Aluminum BIW 39% Lighter than typical ‘01 – ‘03 BIW

Audi A2Audi A2

Audi A8Audi A8

Jaguar XKJaguar XKAudi TTAudi TT

The data also supports the 40% mass savings claim of the aluminum industry



BIW Wt. vs. GVW

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300

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450

1000 1500 2000 2500 3000GVW (Kg)

BIW

(Kg)

'01 - '03 Steel BIWULSAB-AVCAluminum BIW'04 - '08 Steel BIWTop 10 Steel BIW

Since then new vehicle launches have improved on the mass performance of the BIW. Focusing in on the top 10.



The top 10 represent a broad range of vehicle classes and market segments. But have all been designed for the equivalent regulatory requirements and are all excellent performers



BIW Wt. vs. GVW

150

200

250

300

350

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450

1000 1500 2000 2500 3000GVW (Kg)

BIW

(Kg)

'01 - '03 Steel BIWULSAB-AVCAluminum BIW'04 - '08 Steel BIWTop 10 Steel BIW

Advanced Steel BIWsare within 11% of a typical aluminum BIW

Vehicles have achieved the ULSAB-AVC mass targets

The data shows that many vehicle manufacturers are achieving the mass performance of ULSAB-AVC and closing the gap with the aluminum designs to within 11%. Some steel designs exceed the mass performance of aluminum.


Increasing crash requirements

This is a remarkable achievement when we consider the significant increased performance burdens placed on the vehicle structure. However it is these requirements that have enabled the mass competitive of steel with aluminum, moving the structure from a stiffness controlled design to a strength controlled design – a criteria where steel excels

1990 1995 2000 2005 2010

1991FMVSS 208

30MPH Front

2003USNCAP35MPH Front

2012FMVSS 2163.0 X GVW

1994FMVSS 2161.5X GVW

2000SINCAP38.5MPH

Side

1995IIHS

40MPH 40%

1990FMVSS 214

Side

1997FMVSS 201Side Pole

2006IHSS Side

Higher, Heavier Barrier

2006FMVSS30155MPH 70%

2003FMVSS 30150MPH 50%

2009IIHS

4.0 X GVW


2009 Jaguar XF Audi Q7

Aluminum stakeholder turning back to steel

Higher-strength and highest-strength steel

32%26%36%

Standard steel Aluminum High-strength

steel

Jaguar seriously considered using aluminum for the XF. But the XF will make considerable use of high-strength steel, which has come close to achieving aluminum's weight benefits at less cost” says Al Kammerer, product development director for Jaguar and Land Rover.AutoWeek| Published 01/16/07

BMW 7 Series

BMW will use all steel body structure on the next BMW 5 Series and 7 SeriesAutoTech Daily 3/12/09

BMW 5 Series

Vehicle manufacture with a previous strong stake in aluminum have recognized the value proposition of steel and are adjusting their product strategies accordingly.


Prediction for the future

Future Launches

We predict that each new launch will follow this trend and it is clear that vehicle manufacturers will exceed the mass a reduction vision of ULSAB-AVC.


But our work is not done

Global Fuel Economy Targets(normalized to CAFE – Converted to mpg)

2008 2010 2012 2014 2016 2018 2020

MPG

(Equ

ival

ent C

AFE

)

55

50

45

40

35

30

25

20

EU

Japan

USA

California

2008 Current TargetsProposed Targets

Source - WorldAutoSteel FSV Program targets

Mitsubishi IMiev

Chevrolet Volt

Honda Clarity FCX Mercedes F cell

Mercedes E cell

Mercedes E cell Plus

The future fuel economy and CO2 emission requirements and the powertrains required to meet them will increase the demand for and value of mass reduction.



BIW Wt. vs. GVW

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1000 1500 2000 2500 3000GVW (Kg)

BIW

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'01 - '03 Steel BIWULSAB-AVCAluminum BIW'04 - '08 Steel BIWTop 10 Steel BIWEU Super Light Car

EU SLC Materials

Steel36%

Aluminum53%

Magnesium7%

Plastic4%

EU SLC Materials

Steel36%

Aluminum53%

Magnesium7%

Plastic4%

37% Mass Reduction – 112% Cost Increase

Material competition continues and performance demands will continue to challenge steel role in the vehicle.



BIW Wt. vs. GVW

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1000 1500 2000 2500 3000GVW (Kg)

BIW

(Kg)


Future Steel Vehicle• Battery Electric• Plug-in HEV• Fuel Cell


The steel industry will continue to reinvent itself with new technologies and innovations to meet the requirements of the automotive industry. The WorldAutoSteel Future Steel Vehicle program will demonstrate these advances and

set new targets for the performance capability of steel in automotive designs.


BIW Wt. vs. GVW

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1000 1500 2000 2500 3000GVW (Kg)

BIW

(Kg)





Thank you

Questions?


BIW Wt as a Percent of GVW

0%2%4%6%8%

10%12%14%16%18%20%

2001-2003Avg

ULSAB-AVC Steel Top 10 Aluminum Avg

%Addendum Slide

Relative mass values in this presentation are calculated from the average of each category and are as shown here.

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