worldsteel / CISA Jae-Bok NAM

China Automotive Steel Conference POSCO Technical Research Lab.

Development of New Auto Steels and

Application Technology
Nov. 21, 2013

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POSCO Automotive Steel

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 POSCO Automotive Steel
Introduction
 Automotive Steels in POSCO

 Sales in 2003~2012 Sales Mix in 2012

8.0

7.0
Sales of Automotive
Steels, million ton

6.0

5.0
Steel
4.0
Product
Grade
3.0

2.0

1.0

0.0
2003 2004 2005 2006 2007 2008 2009 2010 2011 2012
Coated Product : 33.5% HSS+AHSS : 44.7%

- 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

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 POSCO Automotive Steel
Development of AHSS

Banana Diagram  Conventional AHSS

AHSS grade - DP, TRIP, CP, Mart, HPF
DP/CP
TRIP - TSxEl < 25,000 MPa·%
Mart
Elongation (%)

HPF
TWIP
Duplex/Lightweight  eXtra-AHSS (X-AHSS)
IF
Status - Giga duplex, Light weight steel
Commercialized - 25,000 < TSxEl < 50,000 MPa·%
Mild Developed
Developing
BH
 Ultra-AHSS (U-AHSS)
- TWIP steel
- TSxEl > 50,000 MPa·%

Tensile strength (MPa)

X-AHSS : eXtra-Advanced HSS / U-AHSS : Ultra-Advanced HSS

Ref : Ohjoon Kwon, Kwang Geun Chin et al : Materials Science Forum, Volume THERMEC 2009, p.136

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 POSCO Automotive Steel
490DP Steel for Outer Panel
 GA 490DP for Door Outer – World First Production（2005）
 Requirement : Surface quality, Dent resistance, Stiffness
 Replacement of 340BH steel by 490DP steel
 Weight reduction 7%, improvement of dent resistance 53%

25
0.75mm

Dent load (kgf)

18 20
Weight (kg)

- 7%
15
0.7mm + 53%
17 10
5
16 0
340BH 490DP 340BH 490DP
[ Weight reduction ] [ Improvement of dent resistance ]

Applications

Body panel reinforcement sealer

[ Door outer, 0.7t GA 490DP ] [ Removal of Body panel reinforcement sealer ]

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 POSCO Automotive Steel
590DP Steel for Outer Panel
 GA 590DP for Closure Parts
 Trial for hood outer : 21% weight reduction (0.7t 340BH  0.55t 590DP)
 Trial for fender at Japanese automobile company shows good formability

Applications

Small Sedan, Hood outer

GA 590DP (0.55t)

Japanese Car, Fender

GA 590DP (0.55t)

[ Hood outer using GA 590DP of 0.55mm thickness ]

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 POSCO Automotive Steel
Super Formable IF HSS
 IF HSS (E/ES-class)
 High elongation and excellent r-value
 suitable for outer parts requiring strength & formability

Grade Class YS (MPa) TS (MPa) El (%) r

CR/EG
340E ≥167 ≥ 340 ≥ 32 1.75
GI/GA
CR/EG
340ES ≥180 ≥ 340 ≥ 35 2.25
GI/GA

Application
GI
 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) ]

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 POSCO Automotive Steel
980DP Steel
 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

Bending Spec. Bendability ( GA980DP: 2.0t)

direction (R/t) R/t 0.5R 1.0R 1.5 2.0 2.5 3.0
L ≤ 2.5 1.5 X X △ △ △ O
C ≤ 2.5 1.3 △ △ O △ O O

Applications

[ Back side bracket (CR 980DP) ]

[ Cross section of spot welded GA980DP steel ] [ Floor panel tunnel (GI 980DP) ]
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 POSCO Automotive Steel
1180CP Steel
 GA 1180CP for Reinforcement Parts
Requirement Devloping Target

 High YR  YS ≥ 850 MPa,

 Bendability TS ≥ 1180 MPa
1180CP
 Spot weldability  Bending radius ≤ 3 x thickness
 Zn coatability  Low Ceq and Si content

 Suppress ferrite and promote bainite transformation  High YR, excellent bending property

Applications

 Material Change (EG 590TRIP  GA 1180CP steel)

Ferrite
Martensite  Achieve 33% of weight reduction
 First commercial production in the world

Bainite

[ Microstructure ] [ Rocker Outer (Domestic company) ]

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 POSCO Automotive Steel
GI 1470Mart
 GI 1470Mart for Reinforcement Parts
 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
 Commercialization of the world 1st GI 1470 Martensitic steel
* cf. www.iihs.org

< Mechanical properties >

YS (MPa) TS (MPa) T-El (%) YR Bendability(1）
≥ 1050 ≥ 1470 ≥5 > 0.71 ≤6
1) Bendability = Min. corner radius / Thickness

Applications

 Rocker Outer
 Bumper Beam
[ Rocker Outer (Domestic company)]
 First commercial production in the world

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 POSCO Automotive Steel
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)

Applications

 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) [Bumper Beam, Commercialized product (’12) ]

[ Wheel, Chassis with TWIP steel ]

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 POSCO Automotive Steel
TWIP Steels (U-AHSS)
 Part development of BIW (body in white) and Chassis

BIW Chassis

Spring Stopper

Wheel Disc & Rim

Lower Arm

Front Cross Member

 The red colored parts are made from TWIP steel through collaboration with customers.
 Recently, the number of chassis application is increasing as the advantage becomes
apparent with TWIP steel. .

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 POSCO Automotive Steel
TWIP Steels (U-AHSS)

 Development of TWIP steels with High YS

★ : Commercial, ★ : Developed
1400
70 1200_HY TWIP
★980TWIP 1200
60 1000_HY TWIP
Elongation (%)

1000

Stress (MPa)
50 ★ 900TWIP 900_HY TWIP

800 900TWIP
40 LC
★900_HY TWIP
600
30 BH
★1000_HY TWIP
★1200_HY TWIP 400
20
200
10 CP, MART
HPF

0 0
200 400 600 800 1000 1200 1400 0 20 40 60 80
Tensile Strength (MPa) Strain (%)

 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 .

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 POSCO Automotive Steel
Medium Mn TRIP steel (X-AHSS)
 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 >

YS (MPa) TS (MPa) El (%) TSxEl (MPa%)
980 DP 780 1040 11 11440
980 Duplex 937 1033 28 28924

< Microstructure >

1200

1000
Strength(MPa)

800
Ferrite
600 X-AHSS grade!!
(TS X El ≥ 25,000MPa%)
400 Austenite
200 CR 980 Duplex
0
0 10 20 30
Strain(%)
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POSCO Application Technology
New Forming Technology

Lightweight Solutions for Chassis

POSCO Lightweight Body Concept

Electric Power Train

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 POSCO Application Tech.
New Forming Technology
 Tailored Hot Press Forming
 Implementation : Multi-strength HPF, TWB HPF to enhance the ductility in sepecific area

Multi-strength HPF
HPF1470
(1.5GPa)
③ HSS 590
① HSS 590
HPF1470
(0.6GPa)

(1 Piece Blank)
TWB HPF

HPF1470
Laser welding (1.5GPa)
② HSS 380Y

[ Conventional Design ]
CHSP340Y
(0.6GPa)
(TWB Blank)

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 POSCO Application Tech.
New Forming Technology
 PosRollForm (Multi-Directional Roll Forming)
 Concept : Producing Variable Sectional Profile using
Linear & Rotational Movement of Stands”
 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] [PosRollForm Product]
(Uniform Section) (Variable Section)

Side Sill Floor Cross Member

[PBC-EV PosRollForm Part] [PosRollForm Test Facility]

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 POSCO Application Tech.
Lightweight Solution for Chassis
 Torsion Beam Axle
 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

Project on Torsion Beam Axle Development

Original Beam
Design Optimization
Weight Down+Bracket Removing
Durability Test

PI

Weld Durability Analysis Optimized H/F beam

Proto Beam – Hydro forming FB780 One-piece Beam

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 POSCO Application Tech.
Lightweight Solution for Chassis
 Styled Steel Wheel
 Lightweighting by Shape Optimization and Advanced Manufacturing Technology
 New Concept : High Stiffness Rim (TWIP980 steel + Hydroforming)
TWB Disk (HB780 steel- 3.6t / 3.2t)

TWIP980 Wheel Rim HB780 Wheel Disk

Die design & Forming Analysis Structural / Durability analysis

TWIP980 – Rim Bead Optimization Styled Steel wheel TWB Disk

18
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 POSCO Application Tech.
POSCO Body Concept : PBC-EV
PBC-EV : POSCO Body Concept-Electric Vehicle
 Objectives
 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

Overall Length 4320mm, Wheelbase 2750mm,

Width 1830mm, Height 1550mm

[ Final Styling ]
 Styling & Packages
 CFD Based Styling for Optimal Surface Streamline Separated Air Flow
Aerodynamic Design
 High Roof Package for Maximizing
Passenger/Battery Spaces
 Detachable Rear Battery Package
Cd = 0.285

[ Computational Fluid Dynamic (CFD) simulation ]

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 POSCO Application Tech.
POSCO Body Concept : PBC-EV
 Design Results 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
 Steel Grades
Steel Grades
(As % of Body Weight)

MILD,2.5%

Mg(Sheet),2.0% ETC, 0.53%

E-ES/C/R Class,
32.9%

HPF1470/2000,
8.2% DP490/590/780,
15.6%
CP1180/1470,
10.3%
DP980,
9.3%
TWIP980,
DUPLEX3.9% 10.4% TRIP590,1.6%

TRIP980,1180,
Body Weight : 218 kg 3.3%

Weight Reduction : 26.4% AHSS = 65.0 %

* Body Weight : Without Bumper Impact Beam UHSS(≥1GPa) = 45.4 %
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 POSCO Application Tech.
POSCO Body Concept : PBC-EV
 Manufacturing Process
Manufacturing Process
(As % of BIW Structure Mass)

Cost Efficient Manufacturing

Roll Forming + Forming = 41.2 %
(Including PosRollForm)

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 POSCO Application Tech.
POSCO Body Concept : PBC-EV
 Demonstration

Transition
line

Weldability Test Assembly Ductile Zone Hard

Zone
Weld-line

Process Design &

Formability Analysis HPF1470 CHSP340Y

Process Optimization &

Prototyping
Prototyping

World 1st Body Concept for Electric Vehicle

By Steel Company
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 POSCO Application Tech.
POSCO Body Concept : PBC-EV
 Upgraded Models
1. Solution for RCAR Test 2.1%
※ Max.
Effective Plastic 2.4%
• Effective Solution for RCAR Structural Tests 1.9%
Strain < 0.03
LH : 2.3%

RCAR Front/Rear Structural Test (CAE Result)

2. Extra Lightweight Model Final

• Additional Lightweight by Structure Improvement and Weight
Increase of HPF Parts (HPF ratio in BIW : 8.2  17.1%) Savings
30%
Modified Parts
Design Modification for Extra Lightweight

3. High Torsional Stiffness Model Torsional Stiffness

50%
(kN/deg)
• Torsional Stiffness Improvement : 17.4%

50.0% (17.2  25.8 kN/deg)

25.8
17.2 20.2

Analysis of Strain Energy 218kg 207kg 216kg

& Thickness Sensitiveness PBC-EV Base Extra Light. High Stiff.

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 POSCO Application Tech.
EPT (Electric Power Train)
* PMSM : Permanent Magnet Synchronous Motor
 POSCO EPT system
High Performance and Reliability : PMSM EPT System with High Power Density & High Efficiency
Compact Light Weight Low Cost Easy Installation
High Power Density Key Factor for EV Optimized Design Parts Integration

 Products

100kW EPT – PMSM, PCU 60kW EPT – PMSM, PCU

 Applications to EV (Electric Vehicle)

• EV Conversion for EPT Test
- Various Performance Evaluations
- Road Driving Test
• Mid-size EV Buildup with Customer
• Small Size EV Development in Consortium
POSCO EPT Applications 
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 POSCO Application Tech.
EPT (Electric Power Train)
 100kW PMSM
 Major Specifications
- Motor Type : Interior Permanent Magnet
- Max. Power : 100kW@5,600rpm/90sec
- Continuous Power : 60kW@0~12,000rpm
- Max. Torque : 320Nm/90sec
- Cooling : Water (65Ԩ, 12ℓ/min)
- Power Density : 1.6kW/kg 100kW PMSM (L 286mm  H 325mm  Stator Dia. 260mm, Weight 62kg)

 Performance
T-N Curve Efficiency Map

100kW T-N characteristic  60kW is available

Max Torque 100kW output stably for whole
Max Power speed range
Torque (Nm)

Power (kW)

Cont. Torque Continuous Power

* Avg. 95%
efficiency in most
frequent usable
operating 
** Avg. efficiency
(UDDS LA4mode) :
Motor Speed (rpm) 92% 

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Concluding Remarks

POSCO has been developing new advanced materials

and application technologies for vehicle lightweighting

POSCO develops new technologies, utilizing external

as well as internal resources for customer value creation

POSCO Global R&D Network

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