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gas
Every time the price of steel goes up,
Detroits auto makers moan in anguish
and intensify their search for
replacements
4
Aluminum Alloys
-about as strong as steel,
less than half the weight
-used since birth of auto
-most plentiful metal on earth
Magnesium Alloys
-even lighter than aluminum,
stronger for its weight than steel
-most easily machined and cast
-enough in the ocean
to provide 100,000,000 tons a year
5
Mg
Al
Plastics
Steel
FUTURE
PAST
Oil
Shock
Focus
1950
1960
1970
Global
Competition
1980
1990
Customer
Personalization
2000+
The
C6 Z06the first
19972006
Audi
introduces
Late 1970s Dodge releases
1984 Pontiac releases
Corvette volume
is released.
1953 Chevrolet Introduces the
all
aluminum
production
the Fiero. Small, fuel
XL that
applies higher
Corvette Charger
w/ fiberglass
body.
car.sports
The Aluminum
frames
Utilizes
fiber
efficient
carcarbon
that
strength
and all
aluminum
Lightweight
body steel
improves
up to
less
than
40% of
usesweigh
composite
panels
fenders,
wheel
houses,
components
that resulted in a
aspects of
performance.
to reduce
overall
weight.
steelfloors,
frames
of comparable
and
an aluminum
285kg reduction in vehicle mass.
design.
frame.
8
0%
Mass Reduction
Opportunity
CONV HSS
10%
20%
30%
40%
50%
1970
1980
1990
2000
Time
2010
2020
2030
9
9.5%
Conventional
HSS
Aluminum &
Magnesium
0.8%
12.7%
Mild Steel
Medium
HSS
54.6%
15.8%
6.6%
Bake
Hardenable
Steel
850 Pounds
10
The Question is
Why do these materials continue to fall
short of the prediction?
11
Mild Steel
Modulus
Tensile
Strength
Elongation
Corrosion
Resistance
- - - - - - - - - - BASELINE - - - - - - - - - -
Aluminum
0/+
Magnesium
--
0/-
Polymers &
Composites
0/-
-/0/+
KEY: 0 = equal
+ = better
- = worse
12
Steel
Aluminum
Magnesium
Advantages:
Formability
Weldability
Infrastructure
Painted Surface
Advantages:
Formability
Castability
Painted Surface
Advantages:
Castability
Advantages:
Low cost
tooling
Shorter lead
time
Disadvantages:
Castability
Disadvantages:
Lower
formability than
steel
Weldability
Disadvantages:
Formability
Elevated
temperature
stamping &
hemming
Weldability
Disadvantages:
Cycle Time
Infrastructure
Difficult to
repair
Painted
Surface 13
Comparison of Materials by
Other Important Characteristics
Cost
Availability
Environment
(Est. $/lb.)
Mild Steel
(Baseline)
$0.50
110 Million
easy to recycle
Emissions = 2.3 2.7 kg CO2/kg
Aluminum
(Al)
$1.00
2.5 Million
easy to recycle
Emissions = 13.9 15.5 kg
CO2/kg
Magnesium
(Mg)
$1.50
0.5 Million
easy to recycle
Emissions = 18.0 24.8 kg
CO2/kg
PMC
$1.20 6.50
Unknown
difficult to recycle
Emissions = 2.5 23.0 kg CO2/kg
14
9.5%
Aluminum &
Magnesium
0.8%
12.7%
Mild Steel
Medium
HSS
54.6%
15.8%
Bake
Hardenable
Steel
6.6%
850 Pounds
15
Modulus
Tensile
Strength
Elongation
Corrosion
Resistance
Mild Steel
- - - - - - - - - - BASELINE - - - - - - - - - Aluminum
0/+
Magnesium
--
0/-
Polymers &
Composites
0/-
-/0/+
HSS/AHSS
++
0/-
0
16
Polymer/
Composites
Aluminum
Magnesium
Advantages:
Formability
Weldability
Infrastructure
Painted Surface
Advantages:
Formability
Castability
Painted Surface
Advantages:
Castability
Advantages:
Low cost
tooling
Shorter lead
time
Disadvantages:
Castability
Disadvantages:
Lower
formability than
steel
Weldability
Disadvantages:
Formability
Elevated
temperature
stamping &
hemming
Weldability
Disadvantages:
Cycle Time
Infrastructure
Difficult to
repair
Painted
Surface 17
Comparison of Materials by
Other Important Characteristics
Cost
Availability
Environment
(Est. $/lb.)
Mild Steel
(Baseline)
$0.50
110 Million
easy to recycle
Emissions = 2.3 2.7 kg CO2/kg
Aluminum
(Al)
$1.00
2.5 Million
easy to recycle
Emissions = 13.9 15.5 kg
CO2/kg
Magnesium
(Mg)
$1.50
0.5 Million
easy to recycle
Emissions = 18.0 24.8 kg
CO2/kg
PMC
$1.20 6.50
Unknown
difficult to recycle
Emissions = 2.5 23.0 kg CO2/kg
HSS/AHSS
$0.55
Included in Mild
Steel
easy to recycle
Emissions = 2.3 2.7 kg CO2/kg
18
Steel Strategy
Elongation (%)
70
60
50
IF
40
IF- HS
Mild IS
ISO
O
BH
30
20
10
0
300
Conventional HSS
CM
TRI
HSL
L-I
P
AU
ST
.
A DP, C
P
SS
TW
IP
MART
600
900
Tensile Strength (MPa)
1200
1600
19
Elongation (%)
70
L-I
P
AU
ST
.
60
50
IF
IF-HS
40
Mild ISO
BH
30
20
10
0
CM
TW
Fu
IP
SS
Th
tur
ird
eO
Ge
p
ner portu
atio
nity
TRI
P
nA
HS
HSL DP,
S
CP
A
MART
300
600
900
Tensile Strength (MPa)
1200
1600
20
Fuel Cost
Strategy for material implementation
21
Engineering Strategy
Materials
Design
Manufacturing
22
Business Strategy
Manufacturability
& Cost:
material
design
manufacturing
Government Regulations
Fuel Economy
Crash Performance
Emissions
& Customer Requirements
Cost
Quality/Styling
23
Features
0%
Mass Reduction
Opportunity
CONV HSS
Without DOE
Support
10%
20%
AHSS
30%
40%
50%
FreedomCAR GOAL
1970
1980
1990
Technology
Decision
2000
2010
MASS
COMPOUNDING
3rd GENERATION
2020
2030
Time
24
Global Market
North America
Europe
Fast
growing diverse market
Relatively
low
fuel
prices
Diverse market
U.S.
Relatively
high fuel prices
CAFE
Infrastructure
still developing
Primary
Newchallenges
market players
and emissions regulations
Primary
challenges
are &
new fuel
Taxes
on
poor
fuel
economy
Lead in alternative
fuels,
(particularly
diesel); strict
economy/emission regulations
emissions
particularly
ethanol
collision
performance
requirements
Primary
challenges CO2 commitment
Primary challenge
is product
25
800
U.S.
600
Industrialized Pacific
Western Europe
400
Eastern Europe
U.S. Historic
200
Africa
China
Mid-East
Former Soviet Union
Latin America
Developing Asia
0
1900 1910 1920 1930 1940 1950 1960 1970 1980 1990
China, with 13 vehicles per 1000 people, is where the U.S. was in 1913
Chinas population is currently 4 times the population of the U.S.
26
27
NORTH AMERICAN
LIGHT VEHICLE METALLIC MATERIAL TRENDS
Body and Closure Metallic Material Content by Type
2007
2015
Aluminum &
Advanced
Magnesium
HSS
Con.
9.5% 0.8%
HSS 12.7%
15.8%
Medium
HSS
Aluminum &
Magnesium
Advanced
HSS
2.5%
Mild Steel
29.0%
34.8%
54.6%
Mild Steel
6.6%
10.2%
Bake Hardenable
Conventional
HSS
850 Pounds
23.5%
Bake Hardenable and
Medium HSS
NORTH AMERICAN
LIGHT VEHICLE METALLIC MATERIAL TRENDS
2005
2007
2015
Change From
1975 to 2015
2,180
1,751
1,748
1,314
140
324
334
315
Up 175 lbs.
Advanced HSS
--
111
149
403
Up 403 lbs.
65
76
76
77
Up 12 lbs.
585
290
284
244
84
307
327
374
Up 290 lbs.
--
22
Up 22 lbs.
Other Metals
120
150
149
145
Up 25 lbs.
Plastic/Composites
180
335
340
364
Up 184 lbs.
Other Materials
546
629
634
650
Up 104 lbs.
Total Pounds
3,900
3,982
4,050
3,908*
Mild Steel
Other Steels
Iron
Aluminum
Magnesium
Up 8 lbs.
29
NORTH AMERICAN
LIGHT VEHICLE METALLIC MATERIAL TRENDS
Body and Closure Metallic Material Content by Type
North America
Europe
Aluminum &
Magnesium
Advanced
HSS
34.8%
2.5%
PHS, TWIP
& Others
12.0%
Mild Steel
29.0%
Aluminum &
Magnesium
3.0%
25.0%
30.0%
AHSS
10.2%
Conventional
HSS
23.5%
Bake Hardenable and
Medium HSS
30.0%
Conventional HSS
2015
30
32
Conclusions
Always be a need/desire to push to
lightweight materials for the auto industry
Doesnt mean no steel
Current prediction is mainly some form of
steel
Best value to customer (performance/cost)