ArcelorMittal Global R&D (Hamilton, Canada):

T. Wormald

ArcelorMittal Global R&D (Montataire, France):
N. Schneider, Mag. Eng
E. Gibeau

E-mail (common): redaktion@stahleisen.de

The aim of this study is to demonstrate how intensive use of advanced high-strength steel already in use in the automotive industry can provide high weight reduction for pickup truck structures. This was focussed on advanced steel grades currently available to automotive customers in North America. However, a subsequent investigation also included steel grades currently under development. The goal was to meet or exceed all current stiffness and crashworthiness performance requirements for the full-size pickup vehicle, while achieving a vehicle mass compatible with upcoming 2025 CAFE targets. A complete set of generic performance requirements was built at the beginning of the project, to address crash safety and stiffness requirements for the full vehicle or module constraints to satisfy to in-use-properties and durability. An exhaustive cost analysis was also performed to ensure that the mass savings were achieved at little or no cost penalty. Mass savings for the pickup truck proposal total 174 kg, or a 23% reduction from the structural mass for the baseline vehicle. The contribution of AHSS grades in the solution rose from the baseline of 13% to a total of 63% in the final solution. A large portion of the AHSS content consists of press hardened steels, both the high-strength Usibor 1500 and Ductibor 500 for energy absorption. In total 37 parts were specified as PHS in the final pickup truck bill of materials. For optimal mass efficiency, 17 parts were designed as laser welded blank (LWB) assemblies.

1. FHSA/NHTSA National Crash Analysis Center: Finite Element Model of Chevy Silverado — Model Year 2007 (Version 2), February 2009.
2. A2MAC1 Automotive Benchmarking (A2MAC1.com).