Steel – cost-effective lightweighting for lower CO2 in vehicles

Steel – cost-effective lightweighting for lower CO2 in vehicles

• Proposed 2012 EU CO2 legislation will reward cost-effective lightweighting

• Cars are already 60kg (5%) lighter due to Advanced High Strength Steels (AHSS)

• Developments in place to make further progress

At the IMechE “Lightweighting for carbon-free vehicles” conference, which took place on 23rd April at the Jaguar Assembly Plant in Birmingham, Professor Jon King, Director of Corus Automotive Engineering, explained that steel continues to remain the preferred body structure material for vehicle construction, used in 99% of all new cars in 2007.

Delegates heard that, although the average vehicle is now 50% heavier compared to 40 years ago, the use of Advanced High Strength Steels (AHSS) has provided solutions for cost-effective lightweighting on vehicles over the last 10 years or so, making them up to 60kg lighter, despite the huge improvements in structural safety. Further weight savings due to AHSS deployment are now being realised on many recently launched vehicles, which can equate to a saving of more than one tonne of CO2 over the vehicle’s lifespan.

The forthcoming EU legislation is proposing a 20% reduction in today’s CO2 levels, down to 130 g/km in 2012, with penalties for non-compliance by the vehicle manufacturer determined by a weight-based sliding scale. This switches the focus firmly towards cost-effective lightweighting measures to complement the efforts being made on powertrain efficiency and aerodynamic improvements.  Professor King described the range of AHSS technologies and their attributes that makes steel the most cost-effective material for achieving weight savings in mass production applications.

As a natural consequence, material selection is assuming a greater priority in the vehicle development process. Choices need to be made early as they have a fundamental effect on vehicle architecture and manufacturing assumptions. At a detailed level, the development and use of advanced simulation tools is crucial, as the need for optimisation instead of compromise assumes greater and greater importance.

In his conclusions, Professor King explained: “These results are significant, with steel continuing to be the benchmark material in vehicle body construction. Looking forward to further technological developments and improved collaboration between vehicle manufacturers and their supply chains, huge possibilities exist for additional weight reduction and innovation, as the automotive industry faces increasing pressure and legislative measures to reduce emissions beyond 2012.”

Ends.

Press release can be downloaded from websites: www.automotivepr.com  and www.corusautomotive.com

Corus Automotive media enquiries:

Marco Ferrari +44 (0)207 494 8050                      mferrari@automotivepr.com

Belle Moss +44 (0) 207 494 8050                        bmoss@automotivepr.com

Note to editors:

Corus Automotive

Corus is one of the leading suppliers of steel products, services and technology to the automotive industry. A broad range of Corus steels, ranging from strip and engineering steels to tubes, are used by our customers to make products that are used in body-in-white, closures, chassis and suspension systems, powertrain, seating systems, safety systems, interior trim and other components.  Corus is committed to the global automotive industry, uniquely combining its materials and vehicle engineering knowledge to respond cost-effectively to key drivers of importance to the sector, such as safety, fuel-efficiency, innovation and the environment. The Company actively supports supply chain initiatives that improve efficiency and enhance the value of steel used in automotive applications. For further information, view the Corus automotive website (www.corusautomotive.com).

Corus is Europe's second largest steel producer with annual revenues of over £11 billion and a crude steel production of about 20 million tonnes. With main steelmaking operations primarily in the UK and the Netherlands, Corus provides innovative solutions to the construction, automotive, packaging, mechanical engineering and other markets worldwide. Corus is a subsidiary of Tata Steel, the world's sixth largest steel producer. With the recent acquisition of Corus, the combined enterprise has an aggregate crude steel production capacity of around 28.1 million tonnes with approximately 82,700 employees across the four continents.

Photo caption: Professor Jon King