“ DEVELOPMENT OF HIGH

STRENGTH STEEL ”

Innovation Platform for Auto

Industry
by

B R Galgali – Tata Motors, Pune

S Ghosal – Tata Motors, Pune
INNOVATION?????
• Innovation is doing new things

• Innovation distinguishes a leader and a follower

• Innovation is what, that sparks

•Innovation is the act of introducing something new

• Innovation is the gate of creative destruction

Innovation = Invention + Exploitation

 AUTO and STEEL INDUSTRY
Pioneers in Material Innovation

Out of Every
New 10 Steels
6 Steels are
Automotive
Steels
 Process
Innovation Future Developments..
New Material ULSAS – Ultra Light Steel
Development Auto Suspension

ULSAC – Ultra Light Steel

Auto Closures

ULSAB – AVC Advanced • Weight Savings

Vehicle Concept • No compromise on
performance
• Optimum use of
ULSAB – Ultra Light Steel HSS and processes
Auto Body
Development of High Strength and Ultra High Strength Steel
ULTRA
ULTRALIGHT
LIGHTSTEEL
STEELAUTO
AUTOBODY
BODY
(ULSAB)
(ULSAB)
Consortium
Consortiumofof35
35Steel
Steel
Companies
Companiesunder
underthe
thebanner
banner 1)1)HSS
HSSfor
forWeight
Weight
Of
OfIISI
IISI Reduction
11) )Energy
Energyconservation
conservation Reduction
throughweight
through weight Improved
Improvedcrash
crash
Reduction
Reduction resistance.
resistance.
NASH*****
NASH*****
2)2) Safety
Safety 2)2)Improved
ImprovedProcesses
Processes
a)a) Laser
LaserWelding
Welding
3)3) Fuel
Fuelefficient
efficient b)b) Hydroforming
Hydroforming
(PNGV) c)c) Tailor
(PNGV) Tailorwelded
welded
blanks
blanks
• •Knowledge
Knowledgesharing
sharingthrough-
through-
TATASTEEL
a)a)TATA STEELasasaastrategic
strategicpartner
partner
b)b)International
Internationalconferences
conferences
• •Initial
Initialtryouts
tryoutson
onSUMO
SUMOand and407
407
• •Take
Takeoff off––CUB,
CUB,2626components.
components.
X-1,X-2,
X-1, X-2,Truck
Truckofofthe
theFuture.
Future.
 Drivers for High Strength
Steel Development for
Automotive

Market
Regulation Customers
Demand
• Reduction in • Comfort • Cost Effective
atmospheric • Low maintenance • Feature +
pollution cost • Corrosion
• Safety • Durability and warranty for 6 to 12
• Noise reliability years
• End of life vehicle • Low fuel
recycling consumption
 Material Development
Ultra Light Steel ULSAB and
Automotive Body ULSAB - AVC
Material Process
Development Innovation

Conventional AHSS UHSS Hydroforming

HSS Tailor Welded
Dual Phase TWIP Blanks (TWB)
IFHS Complex Martensitic Hot Stamping
BH Phase
HSLA TRIP
FB Steel
Hot Forming
Quality
 Material Development

Lack of Material
Characterization
Experience
Low Volume of Vendor
Indian Industry Involvement

BARRIERS
Higher Huge Resource
Initial Cost Requirement
Long Horizon
For Development
 Material Development
INNOVATION ???

Inputs
Inputs from
from Innovation
Innovation
ULSAB
ULSAB Platforms
Platforms
Drivers

• Quality
• Weight Reduction
• Safety Development of
of
Development
• Fuel Efficiency DifferentGrades
Grades
Different
OfSteel
Of Steel
 Material Development

Commercial
Introduction with
New Vehicles

Interaction &
Adaptation with
Development of High Strength Existing
Steel
Steel Equipments
TDC finalization Development –
and freezing of Material
material Initial Phase Characterization
specification

Trouble Shooting
•Spring Back Try Out Without
•Cracking Hampering
•Die design Manufacturing
modification etc
 Material Development
Range of High Strength Steel for Automotive
Applications
 Material Development
Impact of High Strength Steel
•Strength 30%
•Door Panels
IFHS350 •Weight 12%
•Fender
•Dent Resistance
•Safety

•Strength 48%
•Rear Wall Panel
IFHS400 •Weight 19%
•Floor Panels
•Dent Resistance
•Safety

•Reinforcements •Strength 63%

IFHS440 •Floor Panels •Weight 25%
•Wheel Arch •Dent Resistance
•Safety
 Material Development
Impact of High Strength Steel
•Strength 118%
•Closure Panels
DP400600 •Weight 47%
•Cab Mtg. Bkt.
•Dent Resistance
•Safety
•Door Panels
•Tailgates •Strength 80%
BH180 •Hood Outer •Weight 20%
& 220
•Fenders •Dent Resistance
•Body Side •Safety

HSLA32 •Reinforcements •Strength 63%

0 and •Floor Panels •Weight 25%
340 •Wheel Arch •Dent Resistance
•Safety
 Material Development
Bake Hardening Steel

Courtesy: United Steel

 Second Generation HSS
Dual Phase Steel

Courtesy: POSCO
 Second Generation HSS
TRIP Steel

Courtesy: POSCO
Process Innovation
 Process Innovations
Hydroforming Process
a b

c d

e f
Faxial Faxial
P

Derived from: Siempelkamp Pressen Systeme Gmb& Co.

 Process Innovations
Design flexibility
Flexible
High material through section
equipments expansion
utilization
(10-40%)

Weight Reduction
Low
production
Why
Dimensional
cost Hydroforming? Control

Compatibility Homogeneous thickness

with any material- distribution and
mild steel, HSS,
higher
stainless steel,
aluminum coated sheets dent resistance
 Process Innovations
Application of Hydroforming
1. Hollow camshaft
2. Radiator frame
3. Engine cradle

10 4. Exhaust System
11 7 8 5. Front axle tube
9
1 6. Space frame
2 6
7. Seat frame
4
8. Rear axle
3 5 9. Suspension member
10. Pillar
11. IP beam
 Process Innovations
Tailor Welded Blanks
• Optimum parts design by
distributing the thickness and
mechanical properties just
where it is required.
• Significant overall weight
saving on the structure.
• Reduction in the
reinforcements and thus
number of small parts.
• Reduction in the overall tooling
cost.
• The appropriate type of blanks
significantly improves the
performance.
• Reduction in the overall
manufacturing cost.
 Process Innovations
Laser Welded Blanks - Roof
Laser
Blank 1 Welding

Blank 2

Avoidance of procurement of wider width

coils and sheets from imported sources
1996-2002 2002-2010 Beyond 2010
 Future Scenario
Trends in High Strength Steel Volume
780 MPa
980 MPa
590 MPa
70%

60%
60% 2004 Actual
440-540 MPa
50%
40%
Usage of HSS (%)

40%
260-270 MPa
30% 340-390 MPa
23%
20%
8%
10%
980 MPa
0%
780 MPa 2015
1979 1992 2004 2015 Forecast
590 MPa 260-270 MPa

Increased high strength steel ratio

and shift to higher strength
occurring simultaneously
440-540 MPa

340-390 MPa
 Conclusions
• Successfully developed and used nine different grades of
high strength steel

• Successfully utilized innovative processes like hydroforming,

laser welding, tailor welded blanks and hot stamping

• Substantial cost reduction through

1. Weight Reduction
2. Reduction in number of components and processes

• Increased reliability and durability

• Improved dent resistance and crash worthiness

“Imagination is more important than knowledge”

Albert Einstein