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The goal of the global steel industry is to open up more space for steel in the future self-driving battery electric vehicle market.
In recent years, the amount of steel used in automobiles has fallen like a rock, and steel manufacturers are looking everywhere for a lifeline. They may have found it in Steel E-Motive, a new fully automatic electric car designed in collaboration with the trade organization WorldAutoSteel and environmental engineering company Ricardo.
Steel does not seem to be the best choice for electric cars in the future, mainly because of its weight. In fact, the global automotive industry is turning to advanced materials, partly because of the search for lightweight auto parts. Lighter weight and higher strength improve the fuel efficiency of gasoline vehicles. The battery life of the electric car version is longer.
This leaves the weird person Iron and Steel excluded. The Automotive Research Center conducted an in-depth study of the lightweight trend. In a recent report, CAR listed the driving factors:
Material system: new low-cost, high-performance composite sandwich structure with honeycomb core, next-generation low-cost carbon fiber, 7xxx series aluminum, third-generation steel, graphene and nanocomposite materials.
Manufacturing: Significantly reduced-high cost-batch fully automated polymer composite manufacturing methods (for example, HP-RTM, spray transfer molding (STM), straight and curved pultrusion, tool-less manufacturing, and high-volume additive manufacturing.
Contributing factors: multi-material (dissimilar material) connections for assembly and disassembly, as well as predictive calculation and design optimization tools.
Ouch! The long battery life conflicts with the time a driver can spend on the steering wheel on a certain day, but the sky is the limit when the fleet vehicles and autonomous driving are mixed. For example, an automated shuttle can transport passengers for 24 hours without charging.
This makes steel a stranger person, but it does not mean that there is no light at the end of the steel tunnel.
WorldAutoSteel is the automotive industry chapter of the World Steel Association. Its membership list includes 20 heavyweights including ArcelorMittal, Hyundai Steel, Tata Steel, ThyssenKrupp Steel and United States Steel.
If you see some overlap between steel manufacturing and automobile manufacturing, it is not an illusion. For example, Hyundai Motor has been producing raw steel for its own auto parts since 2006, while Tata has been tapping the demand for steel cars in India.
This brings us to the E-Motive steel electric car. WorldAutoSteel collaborated with Ricardo to create Steel E-Motive, a futuristic self-driving machine that looks like an escape from a science fiction movie.
The steel-grey color palette of the new electric car is very suitable for the dystopian side of this type, but the color of E-Motive may stand out against the monotonous urban background, which will be a plus for fleet vehicles that double as mobile advertising. .
The idea behind E-Motive electric vehicles is part strategy and part technology.
A ticking clock is driving the strategy because the window for effective action on climate change is closing, and the government (finally) begins to take action. Therefore, E-Motive is designed around feasible technologies and will be available on a large scale by 2030. For WorldAutoSteel, this means steel and more steel.
Here, let us let E-Motive explain:
"Steel will enable engineering teams to meet the operational, safety and environmental requirements of mobility as a service: for example, its strength and formability support the unique low-height lidless integrated battery box, and flat-floor interiors-which also helps For better access.
"The unique rocker arm design can not only provide excellent squeezing force and protection for the occupants, but also provide protection for the internal components of the high-voltage battery.
"Compared with traditional battery packs that use alternative materials, steel also has advantages in cost, weight, and sustainability, while meeting all current and future expected safety standards and regulations."
As for the autopilot angle, they are talking about Level 5.
Ricardo participated in the science-based target program, so the company contributed evidence-based life cycle emissions analysis to this work.
“The life cycle assessment of a vehicle covers the extraction, manufacture, use, and end of life cycle of the product. It also includes the assessment of the energy used to power the vehicle,” Ricardo explained.
According to WorldAutoSteel, so far, steel is winning the emission competition for automotive structural materials.
“Of any material used in automobile structures, steel has the lowest carbon footprint. Compared with other materials, primary steel production emits 7 to 20 times less greenhouse gases,” they said.
They may be doing something, at least for now. For example, compared with steel, carbon fiber manufacturing energy consumption is very high, and it is more difficult to recycle. The light weight and long life of this material can even be used as a score for automotive use, but this situation has not yet been determined.
Fans of hydrogen fuel cell vehicles may be disappointed when learning that E-Motive electric vehicles will use batteries instead of fuel cells.
Nevertheless, there is still a hydrogen twist in the E-Motive story. Which better question can it solve: primary steelmaking or secondary steelmaking?
Primary steelmaking is the most commonly used method today. It involves pushing oxygen into the molten iron, thereby reducing its carbon content. Secondary steelmaking is not common, but the process is still quite common. It uses an electric arc to liquefy iron.
And, this is where it gets interesting. ArcelorMittal has been developing a new electric arc system that uses green hydrogen instead of coal, and it is not the only steel manufacturer turning to green hydrogen (read about the green hydrogen trend here and here More information).
Hyundai has also been working on a hydrogen-powered arc system using green hydrogen. Obviously, the entire steel industry is moving in this direction, so pay close attention to this.
At the same time, E-Motive is not about solving the problems of batteries and fuel cell electric vehicles. This is about deploying existing technologies to reduce greenhouse gas emissions from cars. Cases of using fuel cells in trucks, locomotives, and other heavy-duty applications are being established, but the industry consensus seems to be that car buyers are not yet ready to adopt fuel cell vehicles on a large scale.
With this in mind, let us pay attention to Owain Davies, head of vehicle architecture for the E-Motive project, on the new car battery.
Davies pointed out that fully autonomous electric vehicles can and should use different battery designs around the MaaS (Mobility as a Service) model.
Specifically, E-Motive is designed as a walk-in vehicle with a flat floor, so it feels more like stepping into a subway car rather than sliding into a car.
Davies explained that E-Motive uses advanced high-strength steel (AHSS) from the global steel industry to meet the needs of this particular automotive design method.
"The AHSS solution for high-voltage battery packaging minimizes the deformation of the battery casing, protects modules and power electronics from damage, and reduces the risk of thermal runaway by providing greater thermal containment," he said. "In addition, the use of AHSS gives us greater flexibility when making battery design decisions around the unique vehicle architecture of autonomous MaaS applications."
In terms of safety and performance considerations, Davies listed “many options for battery pack architecture and integration” and “reduced the build cycle time of battery pack assembly from battery to vehicle (tact time refers to the large Mass manufacturing).
All this sounds interesting, but don't hold your breath for E-Motive to enter the mass market. WorldAutoSteel relies on additional battery improvements and other technical adjustments to go live before the 2030 target year.
Follow me on Twitter @TinaMCasey.
Tina specializes in military and corporate sustainability, advanced technologies, emerging materials, biofuels, and water and wastewater issues. The opinions expressed are her own. Follow her on Twitter @TinaMCasey and Google+.
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