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- 0/26 -
Nov. 21, 2013
Development of New Auto Steels and Application Technology
Jae-Bok NAMPOSCO Technical Research Lab.
worldsteel / CISA China Automotive Steel Conference
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Steel GradeProduct
- Sales in 2003 to 2012 has been increasing by CAGR of 11.7%. - In 2012, total sales is 7.3 million tons including 62% overseas sales. - High strength steel and AHSS are occupied with 44.7% of total sales
Sales in 2003~2012 Sales Mix in 2012
HSS+AHSS : 44.7%Coated Product : 33.5%0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
Sale
s o
f A
utom
otiv
e St
eels
, mill
ion
ton
Automotive Steels in POSCO
Introduction POSCO Automotive SteelPOSCO Automotive Steel
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Development of AHSS
Conventional AHSS- DP, TRIP, CP, Mart, HPF- TSxEl < 25,000 MPa·%
eXtra-AHSS (X-AHSS)- Giga duplex, Light weight steel- 25,000 < TSxEl < 50,000 MPa·%
Ultra-AHSS (U-AHSS)- TWIP steel- TSxEl > 50,000 MPa·%
IF
Mild
BH
CommercializedDevelopedDeveloping
Status
DP/CPTRIPMartHPFTWIPDuplex/Lightweight
AHSS grade
Elon
gatio
n (%
)
Tensile strength (MPa)
X-AHSS : eXtra-Advanced HSS / U-AHSS : Ultra-Advanced HSSRef : Ohjoon Kwon, Kwang Geun Chin et al : Materials Science Forum, Volume THERMEC 2009, p.136
Banana Diagram
POSCO Automotive SteelPOSCO Automotive Steel
- 4/26 -
GA 490DP for Door Outer – World First Production(2005)
[ Improvement of dent resistance ][ Weight reduction ]
Requirement : Surface quality, Dent resistance, Stiffness
[ Door outer, 0.7t GA 490DP ] [ Removal of Body panel reinforcement sealer ]
16
17
18
340BH
Wei
ght (
kg)
490DP
- 7%0.75mm
0.7mm
05
10152025
340BH
Den
t loa
d (k
gf)
490DP
+ 53%
Body panel reinforcement sealer
Replacement of 340BH steel by 490DP steelWeight reduction 7%, improvement of dent resistance 53%
490DP Steel for Outer Panel POSCO Automotive SteelPOSCO Automotive Steel
Applications
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Trial for hood outer : 21% weight reduction (0.7t 340BH 0.55t 590DP) Trial for fender at Japanese automobile company shows good formability
Japanese Car, FenderGA 590DP (0.55t)
Small Sedan, Hood outerGA 590DP (0.55t)
[ Hood outer using GA 590DP of 0.55mm thickness ]
GA 590DP for Closure Parts
590DP Steel for Outer Panel POSCO Automotive SteelPOSCO Automotive Steel
Applications
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GI
Grade Class YS (MPa) TS (MPa) El (%) r
340E CR/EG ≥167 ≥ 340 ≥ 32 1.75GI/GA
340ES CR/EG ≥180 ≥ 340 ≥ 35 2.25GI/GA
High elongation and excellent r-value suitable for outer parts requiring strength & formability
340E Steel on Korean OEM’s SIDE OTR PNL
World’s first commercial application
Weight Reduction 7% (EDDQ 0.7t 0.65t)
We have 340ES for better than 340E
[ One Piece Side Outer (domestic company) ]
Super Formable IF HSS
IF HSS (E/ES-class)
POSCO Automotive SteelPOSCO Automotive Steel
Application
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Bending direction
Spec.(R/t)
Bendability ( GA980DP: 2.0t)R/t 0.5R 1.0R 1.5 2.0 2.5 3.0
L ≤ 2.5 1.5 X X △ △ △ OC ≤ 2.5 1.3 △ △ O △ O O
[ Cross section of spot welded GA980DP steel ] [ Floor panel tunnel (GI 980DP) ]
[ Back side bracket (CR 980DP) ]
CR/GI/GA 980DP with good bendability Reduce the strength difference between phases Improvement of bendability Low Ceq decreasing welding nugget hardness Increase of ductility ratio
POSCO Automotive SteelPOSCO Automotive Steel980DP Steel
Applications
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GA 1180CP for Reinforcement Parts
[ Rocker Outer (Domestic company) ]
Material Change (EG 590TRIP GA 1180CP steel) Achieve 33% of weight reduction First commercial production in the world
Martensite Ferrite
Bainite
[ Microstructure ]
Suppress ferrite and promote bainite transformation High YR, excellent bending property
High YR Bendability Spot weldability Zn coatability
YS ≥ 850 MPa, TS ≥ 1180 MPa
Bending radius ≤ 3 x thickness Low Ceq and Si content
1180CP
Requirement Devloping Target
POSCO Automotive SteelPOSCO Automotive Steel1180CP Steel
Applications
- 9/26 -
< Mechanical properties >
Safety regulation for frontal small overlap crash test : 25% offset collision introduced by IIHS So, rocker or side sill becomes more and more
important where anti-corrosion is also significant
* cf. www.iihs.org
[ Rocker Outer (Domestic company)]
GI 1470Mart for Reinforcement Parts
Rocker Outer Bumper Beam
First commercial production in the world
YS (MPa) TS (MPa) T-El (%) YR Bendability(1)
≥ 1050 ≥ 1470 ≥ 5 > 0.71 ≤ 6
1) Bendability = Min. corner radius / Thickness
POSCO Automotive SteelPOSCO Automotive SteelGI 1470Mart
Applications
Commercialization of the world 1st GI 1470 Martensitic steel
- 10/26 -
TWIP Steels (U-AHSS) Characteristics High Mn austenitic steel work-hardened by twinning High energy absorption by excellent strain hardening rate Very high strength-ductility combination (1000MPa, 65%) Commercialization : Cold rolled product, 2011~ (POSCO, World First) Developing high YS TWIP steels (900, 1100, 1300, 1500, 1700 grades)
[Bumper Beam, Commercialized product (’12) ]
[ Wheel, Chassis with TWIP steel ]
High TS, High El : Bumper, member etc. Commercialized Bumper of European Vehicle
(28% weight reduction, 22% cost saving) High HER, High El : Wheel, Low arm etc
- Low arm : 540MPa FB (4 Ops) 980MPa TWIP (2 Ops)
POSCO Automotive SteelPOSCO Automotive Steel
Applications
- 11/26 -
Part development of BIW (body in white) and Chassis
The red colored parts are made from TWIP steel through collaboration with customers.
POSCO Automotive SteelPOSCO Automotive SteelTWIP Steels (U-AHSS)
Lower Arm
Wheel Disc & Rim
Spring Stopper
Front Cross Member
Recently, the number of chassis application is increasing as the advantage becomesapparent with TWIP steel. .
BIW Chassis
- 12/26 -
0
200
400
600
800
1000
1200
1400
0 20 40 60 80
Elo
ngat
ion
(%)
Tensile Strength (MPa)0
10
20
30
40
50
60
70
600 800 1200400 1000 1400
LC
BH
200
CP, MART
★
★
★
★
★
HPF
★ : Commercial, ★ : Developed
Stre
ss (M
Pa)
Strain (%)
900TWIP900_HY TWIP
1000_HY TWIP
1200_HY TWIP
900TWIP
980TWIP
900_HY TWIP
1000_HY TWIP
1200_HY TWIP
To meet the customers needs for high YS TWIP steels, POSCO developed three grades, 900_HY, 1000_HY and 1200_HY, which is utilized work hardening by skin pass rolling .
Development of TWIP steels with High YS
POSCO Automotive SteelPOSCO Automotive SteelTWIP Steels (U-AHSS)
- 13/26 -
0 10 20 300
200
400
600
800
1000
1200
Stre
ngth
(MP
a)
Strain(%)
CR 980 Duplex
YS (MPa) TS (MPa) El (%) TSxEl (MPa%)
980 DP 780 1040 11 11440
980 Duplex 937 1033 28 28924
X-AHSS grade!! (TS X El ≥ 25,000MPa%)
Austenite
Ferrite
Characteristics Medium Mn addition increase of austenite stability High TS strength, yield ratio and elongation with a large amount of austenite Duplex microstructure of ultra-fine retained austenite and ferrite
< Mechanical Properties >
< Microstructure >
Medium Mn TRIP steel (X-AHSS) POSCO Automotive SteelPOSCO Automotive Steel
- 14/26 -
POSCO Application Technology
New Forming Technology
Lightweight Solutions for Chassis
POSCO Lightweight Body Concept
Electric Power Train
- 15/26 -
Implementation : Multi-strength HPF, TWB HPF to enhance the ductility in sepecific area
[ Conventional Design ]
② HSS 380Y
① HSS 590③ HSS 590
Laser weldingHPF1470(1.5GPa)
CHSP340Y(0.6GPa)
HPF1470(1.5GPa)
HPF1470(0.6GPa)
Multi-strength HPF
TWB HPF
(1 Piece Blank)
(TWB Blank)
Tailored Hot Press Forming
POSCO Application Tech.POSCO Application Tech.New Forming Technology
- 16/26 -
POSCO’s own FE Program (Shape-MDRF) : Reduction of Calculation Time with High Accuracy
Unique Solution for the Prevention of Distortion: Incremental Counter Forming Method [Conventional Product]
(Uniform Section)[PosRollForm Product]
(Variable Section)
[PBC-EV PosRollForm Part]Side Sill Floor Cross Member
[PosRollForm Test Facility]
Concept : Producing Variable Sectional Profile usingLinear & Rotational Movement of Stands”
PosRollForm (Multi-Directional Roll Forming)
POSCO Application Tech.POSCO Application Tech.New Forming Technology
- 17/26 -
Removing reinforcement (bracket) for a lightweight torsion beam Design Optimization and Advanced Manufacturing by Hydroforming Technology New Concept : Bended and Expanded Beam for Structural Performance
FB780 One-piece Beam
Project on Torsion Beam Axle Development
PI
Proto Beam – Hydro forming
Design OptimizationWeight Down+Bracket Removing
Original Beam
Optimized H/F beamWeld Durability Analysis
Durability Test
Torsion Beam Axle
Lightweight Solution for Chassis POSCO Application Tech.POSCO Application Tech.
17
- 18/26 -
Die design & Forming Analysis
TWIP980 – Rim Bead Optimization TWB Disk
Structural / Durability analysis
Styled Steel wheel
TWIP980 Wheel Rim HB780 Wheel Disk
Lightweighting by Shape Optimization and Advanced Manufacturing Technology New Concept : High Stiffness Rim (TWIP980 steel + Hydroforming)
TWB Disk (HB780 steel- 3.6t / 3.2t)
Styled Steel Wheel
POSCO Application Tech.POSCO Application Tech.Lightweight Solution for Chassis
18
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To integrate POSCO’s steel products & application tech. to provide Cost Efficient Steel Solutions for electric vehicle to our customers
To identify Requirements of New Steel Grades and New Opportunities for Steel
Dimensions
PBC-EV : POSCO Body Concept-Electric Vehicle
Overall Length 4320mm, Wheelbase 2750mm,Width 1830mm, Height 1550mm
CFD Based Styling for OptimalAerodynamic Design High Roof Package for Maximizing
Passenger/Battery Spaces Detachable Rear Battery Package
[ Computational Fluid Dynamic (CFD) simulation ]
[ Final Styling ]
Cd = 0.285
Separated Air FlowSurface Streamline
POSCO Body Concept : PBC-EV POSCO Application Tech.POSCO Application Tech.
Objectives
Styling & Packages
- 20/26 -
AHSS = 65.0 %UHSS(≥1GPa) = 45.4 %
Steel Grades(As % of Body Weight)
* Body Weight : Without Bumper Impact Beam
Body Weight : 218 kgWeight Reduction : 26.4%
DP490/590/780,
15.6%
DP980,
9.3%
TRIP590,1.6%
TRIP980,1180,
3.3%
TWIP980,
10.4%DUPLEX3.9%
CP1180/1470,
10.3%
HPF1470/2000,
8.2%
Mg(Sheet),2.0%
MILD,2.5%
E-ES/C/R Class,
32.9%
ETC, 0.53%
PBC-EV Base Model
Weight Reduction : 26.4%
Performance : [Crash] 5 Star & Good Safety Rating, No Battery Damage[Stiffness] Static Bending/Torsion > 15000, Dynamic Bending/Torsion = 51.2/47.4Hz
POSCO Application Tech.POSCO Application Tech.
Design Results
POSCO Body Concept : PBC-EV
Steel Grades
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Cost Efficient Manufacturing
Manufacturing Process(As % of BIW Structure Mass)
Roll Forming + Forming = 41.2 %(Including PosRollForm)
POSCO Application Tech.POSCO Application Tech.POSCO Body Concept : PBC-EV
Manufacturing Process
- 22/26 -
World 1st Body Concept for Electric VehicleBy Steel Company
Weldability Test Assembly
Prototyping
Ductile Zone Hard Zone
Transition line
Weld-line
CHSP340Y HPF1470Process Design &
Formability Analysis
Process Optimization &Prototyping
POSCO Application Tech.POSCO Application Tech.POSCO Body Concept : PBC-EV Demonstration
- 23/26 -
1. Solution for RCAR Test 2.1%2.4%
※ Max. Effective Plastic
Strain < 0.03
RCAR Front/Rear Structural Test (CAE Result)
• Additional Lightweight by Structure Improvement and Increase of HPF Parts (HPF ratio in BIW : 8.2 17.1%)
2. Extra Lightweight Model
• Torsional Stiffness Improvement : 50.0% (17.2 25.8 kN/deg)
3. High Torsional Stiffness Model
Modified Parts
Design Modification for Extra Lightweight
FinalWeight Savings
30%
218kg 216kg207kg
25.8
17.4%
50%
17.2 20.2
PBC-EV Base Extra Light. High Stiff.
Torsional Stiffness (kN/deg)
Analysis of Strain Energy& Thickness Sensitiveness
LH : 2.3%1.9%• Effective Solution for RCAR Structural Tests
POSCO Application Tech.POSCO Application Tech.POSCO Body Concept : PBC-EV Upgraded Models
- 24/26 -
Products
Applications to EV (Electric Vehicle)
POSCO EPT Applications
100kW EPT – PMSM, PCU100kW EPT – PMSM, PCU
High Performance and Reliability : PMSM EPT System with High Power Density & High Efficiency
CompactHigh Power Density
Light WeightKey Factor for EV
Low CostOptimized Design
Easy InstallationParts Integration
60kW EPT – PMSM, PCU60kW EPT – PMSM, PCU
• EV Conversion for EPT Test- Various Performance Evaluations- Road Driving Test
• Mid-size EV Buildup with Customer• Small Size EV Development in Consortium
* PMSM : Permanent Magnet Synchronous Motor
EPT (Electric Power Train) POSCO Application Tech.POSCO Application Tech.
POSCO EPT system
- 25/26 -
100kW T-N characteristic
Tor
que
(Nm
)
Motor Speed (rpm)
Pow
er (k
W)Max Power
Continuous Power
Max Torque
Cont. Torque
100kW output
60kW is available stably for whole speed range
T-N Curve Efficiency Map
- Motor Type : Interior Permanent Magnet- Max. Power : 100kW@5,600rpm/90sec- Continuous Power : 60kW@0~12,000rpm- Max. Torque : 320Nm/90sec- Cooling : Water (65 , 12ℓ/min)- Power Density : 1.6kW/kg
Major Specifications
100kW PMSM (L 286mm H 325mm Stator Dia. 260mm, Weight 62kg)100kW PMSM (L 286mm H 325mm Stator Dia. 260mm, Weight 62kg)
Performance
* Avg. 95% efficiency in most
frequent usable operating
** Avg. efficiency (UDDS LA4mode) :
92%
POSCO Application Tech.POSCO Application Tech.
100kW PMSM
EPT (Electric Power Train)