S-in motion® Mid-size Sedan and SUV
The Challenge
• To date, all light steel vehicle solutions have targeted
individual vehicles.
• Light vehicle OEM’s today don’t build one-off vehicles
– they use PLATFORMS that include many vehicle
styles and powertrain options.
• Steel solutions for individual vehicles, therefore, are
of limited value.
2
S-in motion® Mid-size Sedan and SUV
The Solution – S-in motion® Mid-size Sedan and SUV
• A catalogue of steel solutions for a mid-size
PLATFORM that includes both a sedan and a SUV.
• Solutions provide impressive weight reduction.
• At an affordable light weighting cost.
• Meeting all pertinent safety and performance
requirements.
3
S-in motion® Mid-size Objective
Validated loadcases: stiffness and crash requirements including IIHS frontal
small overlap rigid barrier, roof crush, side MDB, side pole as well as FMVSS301
rear crash tests.
S-in motion® Midsize is a catalog of lightweight solutions for Midsize vehicles.
Sedan: 385 kg Sedan: 300 kg
Baseline: NA market representative
Mid-size vehicle
Scope: BIW + Bumpers + door in white
Objective: achieve a 20% weight
reduction at very low cost difference
thanks to advanced high strength steels
SUV: 522 kg SUV: 420 kg
Roof Crush 40% Frontal 25% Frontal Side MDB Side Pole Rear
4
ArcelorMittal products used in this project
ArcelorMittal currently available grades
Essentially AHSS grades
• Dual Phase family
• Complex Phase family
• Usibor®1500
• Laser welded blanks
(especially Usibor®1500
/Ductibor®500)
• MartINsite® family up to
MartINsite® 1700
And also
• DP490 Exposed
ArcelorMittal emerging grades portfolio
• New hot-stamping grades Usibor®2000, Ductibor®1000
• High formability grades Fortiform® 980 and 1180 (980HF, 1180HF)
• MartINsite® 2000
Tensile strength values
2 sets of solutions: one with current grades, one with emerging grades
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NA Mid-size Sedan Benchmarking
Benchmarked vehicles represent
60% of 2013 US Mid-size sales
(5 of top 6 sellers)
Source:
Fusion Accord Malibu Camry Altima
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NA Mid-size Sedan Benchmark & Solutions
7
NA Mid-size sedans
BIW weight without CMS* vs Curb Weight
Aluminum intensive BIW
Vehicle curb weight (kg)
BiW
weig
ht
(kg)
(note: no secondary mass savings were considered for the solution vehicles)
The proposed BIW solutions are very close to aluminum intensive BIW.
S-in motion® Mid-size Sedan baseline
S-in motion®
Mid-size solutions
Source:
* CMS = Crash Management System
(bumper beam and crash boxes)
NA Mid-size Sedan Benchmark & Baseline
Honda Accord SOP 2012 Nissan Altima SOP 2012
S-in motion® Mid-size
Sedan baseline BIW
material breakdown
35% AHSS
+ PHS
Ford Fusion SOP 2013
Source:
Baseline is in line with current NA Mid-size Sedan BIWs (35% AHSS + PHS).
Benchmarked material breakdown values are based on A2Mac1 material analysis
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Tensile strength values
33% AHSS
+ PHS 31% AHSS
+ PHS
39% AHSS
+ PHS
NA Mid-size SUV Benchmark & Solutions
The proposed BIW solution weight is close to aluminum intensive SUV BIW.
Explorer (4x2)
2011 Grand Cherokee
(4x4) 2014
Traverse (4x4)
2011 Highlander (4x4)
2013 Pilot
Pathfinder (4x4)
2014
Source:
NA Mid-size SUV BIWs
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BiW
we
igh
t (k
g)
Footprint (m2)
PHS intensive luxury SUV
Aluminum intensive luxury SUV
SUV baseline
S-in motion® Mid-size SUV solution
Baseline SUV Representation: BIW+CMS*
Mid-size SUV Baseline
The S-in motion® Baseline considers the increase in AHSS use between 2010 and 2015
and therefore represents current state of the art (33% AHSS + PHS + MS).
SOA 2015:
33% AHSS + PHS + MS
Ford Explorer
SOP 2010
Jeep Grand Cherokee
SOP 2010
10
16% AHSS
+ PHS + MS
8% AHSS +
PHS + MS
* CMS = Crash Management System
(bumper beam and crash boxes)
Mid-size Sedan / SUV Platform
S-in motion® Mid-size SUV Guidelines
• Modular approach in regard to the Mid-
size Sedan
• Type of body: unibody
• Worst case for transmission choice in
one model:
o No prop-shaft present for a more
severe intrusions scenario
o 4x4 transmission mass considered
25% of underbody mass of the SUV Solution is carried
over from the Sedan Solution underbody [86 / 241 parts]
Transparent white:
specific SUV parts
Green:
100% Sedan C/O
Blue:
Scaled Sedan parts
(wheelbase + 90mm)
S-in motion® Mid-size SUV S-in motion® Mid-size Sedan
The S-in motion® Mid-size SUV model was built as a platform extension
of the S-in motion® Mid-size Sedan.
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Bandwidth study on 200 kg heavier vehicle
A typical Midsize bandwidth is about 200 kg
comparing lightest I4 FWD to PHEV or AWD version Mass was added on engine and rear structure of S-in motion®
Mid-size Sedan FEM to simulate heaviest vehicle
Baseline
Solution +200 kg
Solution +200kg
Performances on major crash load cases are restored with local reinforcements (+3.7 kg).
No reinforcement required
to meet performance target
Usibor®1500 patch blanks up-
gauged or extended New side sill reinforcements
Cross-member
patch blank
extended
Shotgun
thickness
increased
No reinforcement required
to meet performance target
Roof crush +0.2 kg
SORB +3.5 kg
REAR SIDE
Maximum plastic strain of 9%
in fuel tank (target <15%)
Max level 4.0 UVW B-pillar safety space 18.8 cm
from seat centerline
Per vehicle Per vehicle
+ 150 kg in rear (battery)
+ 50 kg on
engine
Powertrain variants
Curb
weight
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Baseline
Solution +200 kg
S-in motion® Mid-size Sedan
Cost assessment - current grades
The proposed design is about $1/ kg saved higher on cost.
Hypothesis:
• amortization over 5 years
• 300,000 vehicles per year 100% 107%
46%
15%
35%
4%
49%
15%
32%
4%
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Baseline S-in motion® Mid-size Sedan
Sedan Current Steel Grades Solution
Component Total Mass Mass savings
Vehicle weight 1391.8 kg 6%
BIW+CMS 248.2 kg 24%
Front Doors 14.1 kg (x2) 15%
Rear Doors 11.2 kg (x2) 19%
Total 298.8 kg 23%
Baseline Representative of NA Market, Mid-size vehicle
Current Grades Solution
Tensile strength values
86 kg weight reduction
56%
AHSS
(Scope: BIW + CMS + DIW)
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Component Total Mass
Vehicle weight 1478.2 kg
BIW+CMS 324.4 kg
Front Doors 16.5 kg (x2)
Rear Doors 13.9 kg (x2)
Total 385.2 kg
42%
AHSS
Sedan Emerging Steel Grades Solution
Component Total Mass Mass savings
Vehicle weight 1378.0 kg 7%
BIW+CMS 234.5 kg 28%
Front Doors 14.1 kg (x2) 15%
Rear Doors 11.2 kg (x2) 19%
Total 285.1 kg 26%
Baseline Representative of NA Market, Mid-size vehicle
Tensile strength values
(Scope: BIW + CMS + DIW)
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Component Total Mass
Vehicle weight 1478.2 kg
BIW+CMS 324.4 kg
Front Doors 16.5 kg (x2)
Rear Doors 13.9 kg (x2)
Total 385.2 kg
Emerging Grades Solution
59%
AHSS
100 kg weight reduction
42%
AHSS
SUV Current Steel Grades Solution
Component Total Mass Mass savings
Vehicle weight 1944 kg 5%
BIW+CMS 359 kg 19%
Front Doors 16 kg (x2) 20%
Rear Doors 15 kg (x2) 17%
Total 420 kg 20%
Baseline Representative of NA Market, Mid-size vehicle
Current Grades Solution
Tensile strength values
42%
AHSS
(Scope: BIW + CMS + DIW)
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Component Total Mass
Vehicle weight 2046 kg
BIW+CMS 445 kg
Front Doors 20 kg (x2)
Rear Doors 18 kg (x2)
Total 522 kg
33%
AHSS
53%
AHSS
102 kg weight reduction
SUV Emerging Steel Grades Solution
Component Total Mass Mass savings
Vehicle weight 1934 kg 5%
BIW+CMS 349 kg 21%
Front Doors 16 kg (x2) 20%
Rear Doors 15 kg (x2) 17%
Total 410 kg 21%
Baseline Representative of NA Market, Mid-size vehicle
Emerging Grades Solution
Tensile strength values
42%
AHSS
(Scope: BIW + CMS + DIW)
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Component Total Mass
Vehicle weight 2046 kg
BIW+CMS 445 kg
Front Doors 20 kg (x2)
Rear Doors 18 kg (x2)
Total 522 kg
33%
AHSS
112 kg weight reduction
51%
AHSS
DESIGN HIGHLIGHTS
S-in motion® Mid-size Sedan and SUV
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Sedan Current Steel Grades Breakdown
Usibor®1500 – 80.9 kg
PHS > 450MPa - 7.8 kg
MartINsite®1700 – 11.7 kg
DP980 – 9.6 kg DP590 - 15.4 kg
DP490 exposed – 8.5 kg
HSS – 37.9 kg
Mild Steel - 71.1 kg
DP780 and HR780FC – 5.5 kg
Tensile
strength
values
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Sedan Emerging Steel Grades Breakdown
20
Tensile
strength
values
Ductibor® 1000 - 17.4 kg
MartINsite®2000 and 1700 – 11.7 kg
Fortiform®1180 and
DP1180 – 6.4 kg DP780 and HR780 - 3.1 kg
DP490 exposed – 7.9 kg
HSS – 34.2 kg
Mild Steel - 60.8 kg
Fortiform®980 and DP980 – 10.3 kg
Usibor®2000 – 62.6 kg Usibor®1500 – 20.2 kg
SUV Current Steel Grades Breakdown
Usibor® 1500 – 98 kg
Ductibor® 500 – 12 kg
MartINsite® 1700 – 11 kg
DP980 – 38 kg DP780 – 2 kg DP590 – 14 kg
DP490 exposed – 15 kg
HSS – 38 kg
Mild Steel – 131 kg
Tensile
strength
values
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SUV Emerging Steel Grades Breakdown
Usibor® 2000 – 53 kg Ductibor® 1000 – 13 kg
MartINsite® 1700 – 11 kg
Fortiform® 1180 – 15 kg DP780 – 2 kg
DP490 exposed – 15 kg
HSS – 38 kg
Mild Steel – 131 kg Usibor® 1500 – 43 kg
Fortiform® 980 – 26 kg
Ductibor® 500 – 2 kg
Tensile
strength
values
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SUV Front Structure
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Module weight : 88 kg
The solution is 12 kg lighter and meets Small Overlap Rigid Barrier Crash requirement
Small Overlap Rigid Barrier crash rating :
Marginal, with a high risk of “Poor”
downrating due to the leg entrapment
M Small Overlap Rigid Barrier crash rating :
Good G
Solution Module weight : 76 kg
Mass savings : 12 kg (13%) Baseline
Highlight: Small Overlap Test
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The bumper extension and strut
required for a Midsize SUV
S-in motion® Midsize Sedan
S-in motion® Midsize SUV
Strong body side is essential for ‘Good’ rating
Achieved with Usibor ® / Ductibor ®
BASELINE
SOLUTION
Highlight: Laser Welded Shotgun
25
25
Full front US NCAP
Energy
absorption
IIHS Small Overlap
Front Mid Rear
Energ
y
Energ
y (k
J)
DP590 front
soft absorption
zone
DP980 rear
absorption
zone
Dual phase LWB shotgun
Front Mid Rear
Energ
y
Energy
absorption
SUV Front Structure – Rails
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LWB DP590
1.9 / 2.2
LWB HR340LA
1.7 / 1.9
LWB
DP590 1.4 /
DP980 1.6
LWB
DP590 1.4 /
DP980 1.5
DP980
1.3 mm
SUV Front Structure – Shotgun
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LWB
DP590 1.3 / DP980 1.3
/ DP980 1.4
LWB
DP590 0.9 / DP980 0.9
/ DP980 1.0
DP780
1.25
DP780
1.6 DP780
1.6
SUV Front Structure – Bumper
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HR340LA
2.5 mm
HR340LA
2.0 mm
MartINsite®1500
1.5 mm MartINsite®1700
1.4 mm
MartINsite®1500
0.8 mm
DP590
1.4 mm
DP980
1.3 mm
DP590
1.3 mm
DP980
1.4 mm
SUV Bodyside Structure – Door Ring Outer
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Inr + Otr: 57 kg per side
34 kg per vehicle can be saved thanks to AHSS, PHS and laser welded blank solutions.
Baseline Solution Module weight: 40 kg per side
Mass savings: 17 kg (30%)
LWB Door-ring
Usibor® 1500 / Ductibor® 500
CR380LA
Usibor® 1500
DP980
DP980
DP590
DP980
1.3
1.7
1.6
1.4
1.6
1.3
0.8
1.0
DP980
1.4
SUV Bodyside Structure – Inner
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DP780
Usibor® 1500
CR340LA
CR340LA
DP590
DP590
MartINsite® 1300
LWB Usibor® 1500
1.5 / 1.2 / 1.3
LWB Usibor® 1500
0.7 / 1.4 / 0.7
LWB Usibor® 1500
1.7 Usibor® 1500
1.0
Usibor® 1500
0.9
DP980
1.3
DP980 1.3
DP980 1.3
DP980
0.9
DP980 1.2
DP980 1.1
DP980 1.4
34 kg per vehicle can be saved thanks to AHSS, PHS and laser welded blank solutions.
Inr + Otr: 57 kg per side Baseline Solution Module weight: 40 kg per side
Mass savings: 17 kg (30%)
Highlight: Usibor®1500 LWB B-pillar Inner
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Baseline A and B
inner pillars 13 kg
The Usibor® 1500 laser welded B-pillar inner ensures required roof strength
without a supplementary inner reinforcement.
9 kg
Solution A and B
inner pillars
Usibor®
1500
All parts CR340LA, except for
the inner B-pillar reinforcement.
Usibor® 1500
0.7 mm
Usibor® 1500
0.7 mm
Usibor® 1500
1.4 mm
All parts Usibor® 1500
Laser Welded Blanks
SUV Floor Structure
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Baseline Solution Module weight: 61 kg
Module weight: 45 kg
Mass savings: 16 kg (26%)
16 kg mass savings are reached thanks to the intensive use of Usibor® 1500
and press hardened steels Laser Welded Blanks.
DP590
2.0
DP590 1.6
DP590 2.1
Usibor®
1500
1.2 LWB Usibor® 1500
1.5 / 0.85
LWB Usibor® 1500
1.7 / 1.9 / 1.7 / 0.9
LWB
Usibor® 1500 1.1 /
Ductibor® 500 1.4
Usibor® 1500
1.2
Usibor® 1500
1.4
LWB
Usibor® 1500 1.3 /
Ductibor® 500 1.6
Usibor® 1500
1.2
DP600 1.5
CR380LA 1.6
DP980
1.3
DP980
1.3
Highlight: Hot Stamped LWB Cross Member
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Usibor® 1500 and Ductibor® 500 Laser Welded Blanks with Usibor® 1500 tunnel
reinforcement are efficient solutions for side pole crash tests.
5th percentile pole 50th percentile pole
SOLUTION
Ductibor® 500
Usibor® 1500
Anti-intrusion
Energy
Absorption
SUV Rear structure
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Baseline Solution Module weight : 59 kg Module weight: 45 kg
Mass savings: 14 kg (24%)
14 kg mass savings using press hardening grades for the rear crash load path.
CR340LA
1.5
HR420LA
2.0
HR420LA
1.95
HR340LA
1.8
CR270LA
0.9
CR340LA
1.5
CR340LA
1.5
CR3 0.9
LWB
Usibor® 1500 1.7
Usibor® 1500 1.7 (HT700)
Ductibor® 500 1.6
Usibor® 1500
0.95
LWB Usibor®
1500
0.9 / 0.7 / 0.9
LWB CR3
0.6 / 0.9 / 0.6
Usibor® 1500
0.9
MartINsite®
1700
1.4
HR340LA
1.9
Highlight: Hot Stamped LWB Rear Rail
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Hot stamped Laser Welded Blank Rear Rail solution is very effective to meet high speed
rear crash requirement.
Usibor® 1500 1.7 mm or
Usibor® 2000 1.6 mm to
preserve fuel tank integrity
1.7mm Usibor® 1500 partly heat
treated (HT700) or Ductibor® 1000
to manage plastic hinge
Ductibor® 500 1.6 mm or Ductibor® 1000 1.4 mm
with triggers to absorb as much energy as possible
Rear crash FMVSS301
deformable barrier at 80 km per hour
Baseline Solution
Max. value
7.1% Max. value
4.8%
Fuel tank plastic strain
SUV Current Grade – BIW Stiffness
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Load case Load Target Baseline Solution Performance
Torsion
Fz=±844N in
front shock
towers
≥ 20 kNm/º 23.5
kNm/º
22.9
kNm/º
Bending Fz=-4000N on
seat fixations ≥ 10 kN/mm
9.8
kN/mm
13.8
kN/mm
1st Torsion
Mode
Lanczos
Method
Free free
Extraction of
20 modes
1st
EigenMode ≥
37 Hz
40 Hz 40 Hz
1st
Bending
Mode
1st
EigenMode ≥
37 Hz
48 Hz 48 Hz
Solution meets all global stiffness targets thanks to additional stiffening parts, as
well as gauge and adhesive optimization.
OK
Close
to
target
Below
target
SUV Current Grade – Crash Performance
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Solution meets all targets and exceeds baseline performance.
Crash test Target Baseline Solution Performance
Front 100% TTZ > 70 ms
Pulse < 30 g
74 ms
26 g
80 ms
23 g
Small Overlap
25% Intrusion in green area Marginal Good
ODB 40% Intrusion in green area Good Good
IIHS MDB
Side
Intrusion safety > 12.5
cm 18 cm 20 cm
FMVSS 214
Pole Intrusion safety > 0 mm
5th p: 1 mm
50th p: -19 mm
5th p: 74 mm
50th p: 55 mm
FMVSS 301
Rear
< 15% plastic strain on
fuel tank 7% 5%
IIHS Roof
Crush
>4.4 Unloaded Vehicle
Weight (UVW) 5.1 x UVW 4.9 x UVW
OK
Close
to
target
Below
target
Stamping analysis studies
All concepts are feasible with a few minor geometry changes on initial design
Stamping analysis carried out on challenging applications:
• laser welded blanks
• hot stamped parts
• thin gauge parts
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Conclusions
1. ArcelorMittal solutions have reduced the weight of the baseline by 86 kg
(23%) for the Sedan and 102 kg (20%) for the SUV with steel grades
commercially available today.
2. Additional weight savings of 14 kg (26% total weight reduction) for the
Sedan and 10 kg (21% total) for the SUV can be achieved with steel
grades that will be commercially available from ArcelorMittal within less
than two years.
3. Weight savings achieved for large bandwidth, multi-vehicle platform.
4. These solutions can be implemented with only a small cost increase.
5. S-in motion® Mid-size Sedan and SUV solutions can be adapted to
OEM’s specific designs and requirements through co-engineering
projects.
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Acknowledgements
• The S-in motion® Mid-size Sedan and SUV engineering design
projects were led by Ivan Viaux (Sedan) and Florin Arnautu (SUV)
from ArcelorMittal’s automotive R&D lab in Montataire, France. Ivan
and Florin also developed the content for this presentation.
• Contract engineering services were provided by Altair Engineering
for the sedan project, and by Magna Steyr for the SUV project.
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