31
2015 Automotive R&D Event Greg Ludkovsky, VP Global R&D , London June 2015

2015 Automotive R&D Event - Home – ArcelorMittalcorporate.arcelormittal.com/~/media/Files/A/... ·  · 2015-06-022015 Automotive R&D Event Greg Ludkovsky, VP Global R&D , ... value

  • Upload
    dokiet

  • View
    212

  • Download
    0

Embed Size (px)

Citation preview

2015 Automotive R&D EventGreg Ludkovsky, VP Global R&D , London June 2015

DisclaimerForward-Looking Statements This document may contain forward-looking information and statements about ArcelorMittal and its subsidiaries. These statements include financial projections and estimates and their underlying assumptions, statements regarding plans, objectives and expectations with respect to future operations, products and services, and statements regarding future performance. Forward-looking statements may be identified by the words “believe,” “expect,” “anticipate,” “target” or similar expressions. Although ArcelorMittal’s management believes that the expectations reflected in such forward-looking statements are reasonable, investors and holders of ArcelorMittal’s securities are cautioned that forward-looking information and statements are subject to numerous risks and uncertainties, many of which are difficult to predict and generally beyond the control of ArcelorMittal, that could cause actual results and developments to differ materially and adversely from those expressed in, or implied or projected by, the forward-looking information and statements. These risks and uncertainties include those discussed or identified in the filings with the Luxembourg Stock Market Authority for the Financial Markets (Commission de Surveillance du Secteur Financier) and the United States Securities and Exchange Commission (the “SEC”) made or to be made by ArcelorMittal, including ArcelorMittal’s Annual Report on Form 20-F for the year ended December 31, 2014 filed with the SEC. ArcelorMittal undertakes no obligation to publicly update its forward-looking statements, whether as a result of new information, future events, or otherwise.

1

Agenda

• R&D overview

• Product development

• Manufacturing technology optimization

• Design and co-engineering

• Summary

2

3

2014 R&D spend of $260m (1/3 for automotive sector)2014 R&D spend of $260m (1/3 for automotive sector)

• Over 1,300 full time researchers

• Working on all process and development needs

• Expanding worldwide network of laboratories (currently 12 labs in Europe, North America, and South America)

• Key challenges fully aligned with the group strategy: geography, value chain, product differentiation

57% Product37%Process

6%Exploratory

General industry10%

Construction

Plates and specialities13%

10%

Others7%

60%Automotive

R&D budget spending by need

Global R&D key facts and figures

Six R&D labs dedicated to automotiveindustry

CanadaHamilton

USAEast Chicago

BrazilTubarão**

FranceMaizières-lès-Metz MontataireGandrange*

* Focus on R&D for Long Products** Focus on steel innovations for the automotive, energy, construction, machinery and white goods industries.

4

Main missions:• Develop new steels• Improve the in-use properties of steels• Find anti-corrosion solutions• Invent breakthrough products• Ensure technical service to customers• Predict the behaviour of steel

565 people are adapting steel to the evolution of automotive industry needs565 people are adapting steel to the evolution of automotive industry needs

5

Committed co-engineering programs with key customersCommitted co-engineering programs with key customers

Dedicated resident engineers bring technical support to global customers

ArcelorMittal also has six mobile Early Vendor Involvement (EVI) engineers with a global remit responsible for processing and providing stamping and joining support

6 resident engineers

1 resident engineer

3 resident engineers

1 resident engineer

1 resident engineer

1 resident engineer

1 resident engineer

14 resident engineers1 resident engineer

North AmericaUnited Kingdom

France

Spain

Italy

India

China

Japan

Republic of Korea

Brazil

3 resident engineers

2 resident engineers

Germany

Our vision and approach

OUR VISION

OUR WAY

From Collaboration to Co-creation

More thanSteel

Non-Stop R&D investment

Mastering Steel: Referential Engineering Material

Cutting-edge Technology Expertise Out-of-the-box Design

Capacity

R&D mission R&D mission 6

7

Product development

© A

rcel

orM

ittal

201

4 –

All

right

s re

serv

ed fo

r all

coun

tries

Can

not b

e di

sclo

sed,

use

d, o

r rep

rodu

ced

with

out p

rior w

ritte

n sp

ecifi

c au

thor

izat

ion

of A

rcel

orM

ittal

Through innovation, steel remains thematerial of choice

• ArcelorMittal has developed a unique full range of coated Advanced High Strength Steels in the last 25 years

• This has had significant impact on automotive construction:– Safety: Most vehicles get 5 stars NCAP rating today– Weight saving: Body structures are 25% lighter than in the 1980s– Environment: 6% less greenhouse gas emissions than in the 1980s– Corrosion protection: 12 years is the mainstream guarantee for corrosion thanks to the

huge share of coated products

1990 2008 2014

1st Generation, phase 1: HSLA, HSS

1st Generation, phase 2 : Dual Phase (DP1180 since 2008), TRIP Steels, Martensitic(MS>1200MPa since 80’s)

1st Generation, phase 3: Usibor® for hot stamping

3rd Generation AHSS Fortiform® for cold stamping

2nd Generation: TWIP, X-IP

20031993

8

ArcelorMittal has developed the broadest product offer in the worldArcelorMittal has developed the broadest product offer in the world

9

• Lightweight design of vehicles with hot stamping of Alusi pre-coated Usibor®

boron steel– Very high strength (Up to 2000MPa tensile

strength)– No springback, complex parts are feasible– Very good corrosion-resistance– Huge weight-saving potential for anti-

intrusion parts (up to 30%)– Tailored properties with Laser Welded

Blanks (LWB) with Ductibor®

– Very fast growth all over the world

-

Potential usage of hot-stamping technology(S-in motion® concept)

Potential usage of Laser Welded BlanksUsibor® - Ductibor® (S-in motion® concept)

Heated blanks before hot stamping

Press hardenable steels for automotive

Press hardenable steels have become a mainstream solution for weight saving Press hardenable steels have become a mainstream solution for weight saving

Penetration of press hardened steels

Volkswagen Golf

10

80%66%

28%

6%

Golf VIIGolf VI

UHSSHSS

Armin Plath, Head of Materials Research and Manufacturing, Volkswagen

“Volkswagen is using high strength steels in increasing amounts. It is a very cost effective way of reducing weight. Using new innovations in steel engineering… it is possible to reduce weight without the use for more costly materials such as aluminum and carbon fiber.”

According to an interview with Volkswagen for Truth About Cars, Volkswagen found that new HSS are:• Six times stronger than conventional steels they replace• Instrumental in achieving a weight reduction of 100 lbs. in the 2013 VW Golf“Volkswagen replaces aluminum with steel to save weight and money,” by BertelSchmitt, Truth About Cars, Jan. 2013

High strength-steels share: from 66% in Golf VI to 80% in Golf VII

Ultra high-strength steel share: from 6% to 28% (24% PHS, 4% AHSS)

VW: constant progress in weight primarily due to Advanced High Strength SteelsVW: constant progress in weight primarily due to Advanced High Strength Steels

Volvo XC90 275 pounds lighter than its

predecessor and 440 pounds lighter than most of its competitors .

60%

40%

Other

Press hardened steels

XC90's body & components structure

Quote from Volvo’s statement on 22 July 2014:“To help keep the occupant space inside

intact in a crash, the all-new XC90 has literally been made stronger in every sense. This is achieved by more extensive use of hot-formed boron steel, which is the strongest type of steel presently used in the car body industry.

The complete safety cage around the occupants is made from hot-formed boron steel and is designed for maximum occupant protection in all types of crash scenarios. The hot-formed steel amounts to about 40 per cent of the total body weight.”

11

Penetration of press hardened steels

40% of the Volvo XC90 uses press hardened steel – the most in any vehicle40% of the Volvo XC90 uses press hardened steel – the most in any vehicle

12

• For more than 20 years, weight saving solutions have been developed through the regular increase of tensile strength of the Advanced High Strength Steels

• Increase of strength is generally done at the expense of formability (complexity of shapes)

• ArcelorMittal has developed 2 ways to change the game:• Usibor® and Ductibor® hot stamping

solutions• Fortiform® for cold stamping with

outstanding combination of formability and strength

Part stamped with Fortiform®

Broadening our product portfolio

ArcelorMittal automotive steel: various products offer formability and strengthArcelorMittal automotive steel: various products offer formability and strength

13

Recap

• Two major products research centers: Maizières-lès-Metz (France) and East Chicago (USA)

• Managing a global product catalogue• Cloning the existing solutions in the various regions (Europe,

NAFTA, South America, Asia) to extend availabilities• Working within a global project structure to develop simultaneously

the emerging grades in Europe and NAFTA

Globalization of product portfolio

ArcelorMittal offers a really global product portfolioArcelorMittal offers a really global product portfolio

14

Recap

• iCARe® is ArcelorMittal’s range of innovative electrical steels for the automotive market: Save: reduces energy losses Torque: for the highest levels of mechanical

power output through high permeability Speed: high strength electrical steels for high

speed rotors • Large number of products in the iCARe® range

provide technical solutions for automakers: Lower CO2 emissions and better fuel

consumption for hybrid vehicles Longer drive range Lower total cost of electrification Better power density of electric machines -

reduces size and weight of electrical drive trains

Plug-in Hybrid Volkswagen Golf

iCARe®: Steels for electrical mobility

Electrical steel solutions for all types of electric vehiclesElectrical steel solutions for all types of electric vehicles

15

Manufacturing technology optimization

16

Recap

Materials, thicknesses and weldline positions can be tuned to optimize weightMaterials, thicknesses and weldline positions can be tuned to optimize weight

Honda’s Acura MDX

Innovative door ring concept- Mass savings

Innovative developments to guarantee the weld qualityInnovative developments to guarantee the weld quality

• Before laser-welding, the aluminium-silicon coating near the edge is partially ablated by laser (ArcelorMittal process)

• The top layer is removed to avoid excessive Al dilution in the weld• The intermetallic layer is intentionally kept to guarantee corrosion protection

Blank B Blank A

AlSi Coating

Weld

Remaining thin intermetallic layer

~ 2 mm

1 – 1.5 mm

~ 1 mm

Laser coating ablation

Laser welding

This process allows uniform hardness distribution after hot stamping, guaranteeing the weld quality

ArcelorMittal developed a process for Usibor® laser welding

17

18

Outstanding performances regarding weight and fuel economyOutstanding performances regarding weight and fuel economy

Hot stamped door ring - Honda’sAcura MDX

8.6 lbs. weight reduction per door, reducing 2014 fleet by ca. 600,000 lbs Improved fuel economy: 18/27 MPG for 2014 Acura MDX (AWD, V6) vs. 16/21

MPG for 2013 Offers improved energy management through uninterrupted joints for smooth

load path

“Weight was one of the ways to improve fuel economy. Taking weight out of a car and making a car stronger is not an easy thing. In spite of being a much stronger, safer car, it is 275 pounds lighter than the outline car.”

Jim Keller, 2014 Acura MDX Chief Engineer

19

Design without hot stamped door ring Design with hot stamped door ring

2014 Acura MDX2013 Other OEM

Small offset crash performance comparison• Note deformations in the door opening area on comparison vehicle: ability to open the driver side door after the crash event in 2014 Acura MDX

IIHSIIHS

Honda’s Acura MDX received the highest available safety ratingsHonda’s Acura MDX received the highest available safety ratings

2014 Honda Acura MDX crash test

20

Door ring project awardedDoor ring project awarded

American Metal Market’s 2014 Best Innovation Process Award for the Honda door ring

Automotive News' 2014 PACE Award in the Manufacturing Process and Capital Equipment category for the laser ablation process

Delegation from ArcelorMittal and Magna Cosma Int’l

Award winning solutions

21

Design and co-engineering

22

A long tradition of steel solution developmentA long tradition of steel solution development

From a steel provider, to a global solution provider

ArcelorMittal’s leadership as solution provider recognized by OEMs

S-in motion®

C-Segment Vehiclesdemonstrates the potential of AHSS & PHS

1990 2004 2010 20142013

S-in motion®

Electric & Plug-in Hybrid C-Segment Vehicles

Contribution to ULSAB/ULSAC industry-wide lightweight effort

ArcelorMittal’s ABC lightweight project

S-in motion®

Pickup Trucks

2012

S-in motion®

Light Commercial Vehicles

23

3 step methodology for co-engineeringBIW review

Preliminary mass-saving assessment

Refinedmass-saving

analysis

Forming& weldingfeasibility

PHASE 1 PHASE 2 PHASE 3

Identification of potential mass saving solutions thanks to:

Benchmark

Steel grade properties

Engineered solution projects

Grade, Gauge & Geometry optimization thanks to numerical simulations

Crash FE analysis

Stiffness FE analysis

Forming and assembly assessment

Springback counter measures

Hot-forming

Roll-forming

Spot-welding

Laser Welded Blanks

24

• A catalogue of 60 steel solutions using:– Advanced High Strength Steels– Hot stamping– Laser Welded Blanks– Tubular products– Long products

• Enabling:– to save up to 73 kg or 20% of a typical

C-segment vehicle’s body-in-white and chassis weight

– to deliver a 13.5% reduction in CO2 equivalent (eq) emissions during the vehicle’s use-phase

– to achieve these savings at neutral cost without compromising the vehicle’s safety performance

S-in motion®: weight reduction solutions

54% AHSSProcesses• Hot stamping 29 parts• Stamping of LWB 16 parts • Roll forming 2 parts

Press hardened parts (Usibor®/Ductibor®)

Choose the best weight saving / cost compromisesChoose the best weight saving / cost compromises

• 174 kg (23%) of weight savings compared to baseline weight (748 kg)

• Optimal solution embarks 63% Advanced High Strength Steels including 18% Press Hardened Steels

• Solutions are validated for crash and stiffness requirements

• Main complex parts are validated for forming and assembly

22kg additional weight saving with emerging grades22kg additional weight saving with emerging grades

S-in motion® Pickup Trucks

S-in motion® Pickup Trucks

25

Weight: 13.3 kg Weight savings: 4.9 kg / 27%

Cost savings vs Alu: 30%

Steel grades

Weight breakdown

Baseline Front Door S-in motion® S1 Lightweight Steel Door

Short term Ultra lightweight steel door - Market ready

14.5kg18.3kg 12kgMedium termShort term

C-segment vehicle

13.3kg

1. Door innerLaser welded blank AM05 0.8mm /0.6mm

2. Waist beamMS1500 0.9mm & DP780

3. Door beamUsibor®1500

4. Hinge reinforcementsUsibor®1500

5. Outer panelFF280DP (490DP) 0.6mm

Tensile strength values

Opening the door to more weight savingsOpening the door to more weight savings

S-in motion® Ultra Lightweight Steel Door

26

27

Mike Sweers, Chief Engineer for Toyota’s North American truck division:"If you are designing properly for the material, you can achieve the proper weight savings. If you just try to make the mass reduction purely by material itself, you’ll reduce weight but won’t optimise it. It all really starts with design."

Peter Mertens, Senior Vice President of research and development for Volvo“Volvo prefers boron steel to aluminum because of the strength properties and the added safety in a crash.”

Armin Plath, VW’s head of materials research and manufacturing:“Volkswagen is using high-strength steels in increasing amounts. It is a very cost effective way of reducing weight.”

Customer testimonials

28

Key takeaways

• We understand the challenges and proved that steel can meet these challenge

• We have products and market position to capture growth• By leveraging the resources of our global R&D organization, ArcelorMittal has

become a unique provider of steel solutions for the automotive market:• a broad global product offer, constantly in evolution • a high level expertise in all processes and in-use properties • an incomparable ability to provide highly engineered solutions for

weight and cost savings• Advanced technological capabilities (Usibor® for hot stamping / Laser

Welded Blanks and Fortiform® range of 3rd generation AHSS for cold stamping) • We are convinced that steel will remain the preferred material for car

manufacturing due to its unique ability to bring affordable weight savingsolutions

• We are investing to back this franchise business

Steel to remain material of choice for automotive industrySteel to remain material of choice for automotive industry

Q&A

Daniel Fairclough – Global Head Investor [email protected]+44 207 543 1105

Hetal Patel – UK/European Investor [email protected]+44 207 543 1128

Valérie Mella – European/Retail Investor [email protected]+44 207 543 1156

Maureen Baker – Fixed Income/Debt Investor [email protected]+33 1 71 92 10 26

Lisa Fortuna – US Investor [email protected]+312 899 3985

We have released a new ArcelorMittal investor relations app available for download on IOS or android devices

New ArcelorMittal IR app and contacts