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"Material Challenges Facing the Automotive and Steel Industries from Globalization"
Curt D. HorvathTechnical Fellow
General Motors Corporation
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Globalization
• Producing very large “Global Powerhouses”• Leveraging global resources to improve
efficiency
• Global sharing of products
The Global Automotive Industry
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GM’s Global Footprint
CANADATrucks & Cars
USATrucks & Cars
MEXICOTrucks and Cars
VENEZUELATrucks
ColumbiaTrucks
ECUADORTrucks and Cars
BRAZILTrucks and Cars
CHILETrucks
ArgentinaTrucks
PORTUGALCars
SPAIN Cars
U.K. Trucks & Cars
BELGIUM Cars
SWEEDEN Cars
SAAB
GERMANY Cars
POLAND Cars
HUNGARY Cars
TURKEY Cars
RUSSIA Trucks
JAPAN IZUZU
TRUCKSCHINA Cars
TAIWAN Cars
THAILANDCars
AUSTRALIA Holden Cars
INDONESIA Cars & Trucks
• Assembly Locations in Over 32 Countries• Products Sold in 170 Countries
• Annual Volume of 9.1 Million Vehicles
Willow Run, MI
Willow Run, MI
Bay City, MIBay City, MI
Tonawanda, NY
Tonawanda, NY
Toluca, Mexico 1&2
Toluca, Mexico 1&2
Defiance, OH
Defiance, OH
Sao José, BrazilSao José, Brazil
Port Melbourne, Australia
Port Melbourne, Australia
Shanghai, China
Shanghai, China
Fredericksburg, VA
Fredericksburg, VA
Lansing Metal, MILansing Metal, MI
Doraville, GADoraville, GA
Pittsburgh, PAPittsburgh, PA
Silao, MexicoSilao, Mexico
MassenaMassena
Sao Caetano do Sul, Brasil
Sao Caetano do Sul, Brasil
GM South Africa 1GM South Africa 1
Saab, Trollhattan, SwedenSaab, Trollhattan, Sweden
Bochum, GermanyBochum, Germany
Elizabeth, Australia
Elizabeth, Australia
Rayong, Thailand
Rayong, Thailand
Elizabeth, South AustraliaElizabeth, South Australia
Halol, IndiaHalol, India
Bekasi Indonesia*Bekasi Indonesia*Rayong, ThailandRayong, Thailand
Antwerp, BelgiumAntwerp, Belgium
Eisenach, GermanyEisenach, Germany
Trollhattan, Sweden
Trollhattan, Sweden
Ellesmere Port, UK
Ellesmere Port, UK
Kaiserslautern, Germany
Kaiserslautern, Germany
Russelsheim, GermanyRusselsheim, Germany
Aspern, Australia
Aspern, Australia
Biala (Bielsko), Poland
Biala (Bielsko), Poland
Gliwice, PolandGliwice, Poland
Sao Caetano do Sul, BrazilSao Caetano do Sul, Brazil
Sao Jose dos Campos, Brazil
Sao Jose dos Campos, BrazilRosario, ArgentinaRosario, Argentina
Arica, Chile*Arica, Chile*
Quito, Ecuador*
Quito, Ecuador*
Bogota, Colombia*
Bogota, Colombia*
Valencia, Venezuela*
Valencia, Venezuela*
AMT South Lyon, MIAMT South Lyon, MI
Indianapolis, INIndianapolis, IN
Arlington, TXArlington, TX
Ramos Arizpe 1 & 2, MexRamos Arizpe 1 & 2, Mex
Baltimore, MDBaltimore, MD
Bowling Green, KYBowling Green, KY
Doraville, GADoraville, GA
Ramos Arizpe, Mexico
Ramos Arizpe, Mexico
Shreveport, LAShreveport, LA
Spring Hill, TNSpring Hill, TN
Shreveport, LA
Shreveport, LA
Silao, MexSilao, Mex
Linden, NJLinden, NJToledo, OH
1&2Toledo, OH
1&2
Wilmington, DEWilmington, DEMoraine, OH -JV
Moraine, OH -JV
Lordstown, OHLordstown, OH
Mansfield, OH
Mansfield, OH
Moraine, OHMoraine, OH
Pontiac, MIPontiac, MI
Orion, MIOrion, MI
Lansing M, MILansing M, MI
Saginaw , MI 1&2Saginaw , MI 1&2
Flint, MIFlint, MI
Grand Blanc, MIGrand Blanc, MI
Janesville 1 & 3, WIJanesville 1 & 3, WI
Wentzville, MOWentzville, MO
Oklahoma City, OKOklahoma City, OK
BedfordBedford
Parma, OHParma, OH
Fort Wayne, INFort Wayne, IN
CAMI-Ingersol, ONT
CAMI-Ingersol, ONT
NUMMI-Fremont, CANUMMI-Fremont, CA
Oshawa Truck, ONTOshawa Truck, ONT
Oshawa 1 & 2, OntOshawa 1 & 2, Ont
Lansing Craft Center, MILansing Craft Center, MI
Lordstown, OHLordstown, OH
Nairobi, Kenya -CKD
Nairobi, Kenya -CKD
Lagos, Nigeria -CKD
Lagos, Nigeria -CKD
CJSC, Zaporoche, UkraineCJSC, Zaporoche, Ukraine
IBC, Luton, UKIBC, Luton, UK
Tychy – ISPOL, Poland
Tychy – ISPOL, Poland
Szentgotthard, Hungary
Szentgotthard, Hungary
AvtoVAZ, Togliatti, RussiaAvtoVAZ, Togliatti, Russia
Qingdao, China
Qingdao, China
Azambuja, Portugal
Azambuja, Portugal Shanghai N&S,
ChinaShanghai N&S,
China
Changwon, S. Korea
Changwon, S. Korea
Gunsan, S. KoreaGunsan, S. Korea
Hanoi, Vietnam
Hanoi, Vietnam
Liuzhou, China
Liuzhou, China
Shanghai, China
Shanghai, China
Ramos Arizpe, Mexico
Ramos Arizpe, Mexico
Wentzville, MOWentzville, MO
Mishawaka, INMishawaka, IN
Fairfax, KSFairfax, KS
Romulus, MI 1#2
Romulus, MI 1#2
Fairfax, KSFairfax, KS
Marion, INMarion, IN
Heuliez, Cerizay, France
Heuliez, Cerizay, France
Bertone, Torino, Italy
Bertone, Torino, Italy
Steyr, Graz, Austria
Steyr, Graz, Austria
Barcelona, Spain
Barcelona, Spain
Tunis, Tunisia -CKD
Tunis, Tunisia -CKD
Bupyeong 1 & 2, S.Korea
Bupyeong 1 & 2, S.Korea
Changwon, S. Korea
Changwon, S. Korea
Bupyong, KoreaBupyong, Korea
Bupyeong, S. KoreaBupyeong, S. Korea
Warren, MIWarren, MI
Baltimore, MD
Baltimore, MD
Indianapolis, IN
Indianapolis, IN
Zaragoza, SpainZaragoza, Spain
Strasbourg, France
Strasbourg, France
Zaragoza, Spain
Zaragoza, SpainSpring Hill, TNSpring Hill, TN
Flint, MI 1,N&S
Flint, MI 1,N&S
St. Catharines,ONT 1&2
St. Catharines,ONT 1&2
Detroit-Hamtramck, MIDetroit-Hamtramck, MI
Windsor, ONTWindsor, ONT
Silao, MexicoSilao, Mexico Toluca, MexToluca, Mex
Spring Hill 1 & 2, TNSpring Hill 1 & 2, TN
Gravatai, BrazilGravatai, Brazil
Lansing Grand River, MILansing Grand River, MI
Pontiac, MIPontiac, MI
Lansing Tooling, MI
Lansing Tooling, MI
Flint 1 & 3, MIFlint 1 & 3, MI
Hethel, England
Hethel, England
Oshawa, ONT, CanadaOshawa, ONT, Canada
Renault, Batilly, France
Renault, Batilly, France
Kaiserslautern, GermanyKaiserslautern, Germany
Ellesmere Port, England
Ellesmere Port, England
Russelsheim, GermanyRusselsheim, Germany
Antwert, BelgiumAntwert, Belgium
Luton, EnglandLuton, England
Bochum, Germany
Bochum, Germany
Soedertaelje, SwedenSoedertaelje, Sweden
Gothenburg, Sweden
Gothenburg, Sweden
Bochum, Germany
Bochum, Germany
Russelsheim, Germany
Russelsheim, Germany Gliwice, PolandGliwice, Poland
6 October City, Egypt6 October City, Egypt
STSW, MISTSW, MI
Grand Rapids, MI
Grand Rapids, MI
Sao Jose dos Campos, Brasil
Sao Jose dos Campos, Brasil
Gravatai, BrasilGravatai, Brasil
GM South Africa 2GM South Africa 2
Wixom, MIWixom, MI
Yantai, ChinaYantai, China
Shenyang, China
Shenyang, China
Gunsan, S. Korea
Gunsan, S. Korea
Changwon, KoreaChangwon, Korea
Boryong, KoreaBoryong, Korea
Yanati, ChinaYanati, China
Yantai, China
Yantai, China
Qingdao, ChinaQingdao, China
Liuzhou, China 1&2
Liuzhou, China 1&2
Lansing Regional. MILansing Regional. MI
Parma, OHParma, OH
Livonia, MI
Livonia, MI
Rosario, Argentina
Rosario, Argentina
Mogi das Cruzes, Brasil
Mogi das Cruzes, Brasil
Rosario, ArgentinaRosario, Argentina
Lansing C, MILansing C, MI
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Enablers for Resource Leveraging
• Common vehicle development process
• Common engineering process
• Common manufacturing process
The Global Automotive Industry
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Primary Building Blocks for Commonization
• Enabler for common engineering andmanufacturing processes
• Common materials and specifications provide a global “language” for requirements
The Global Automotive Industry
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Global Specifications – Benefits
The Global Automotive Industry
• Reduce development, manufacturing and validation costs
• Enabler for global architectures
• Assist in moving into developing markets
• Improved productivity
• Improved quality
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Complex Material Landscape
SAE/ASTM – High Strength Steel
- Focus on Yield Strength
- YS-Steps: Not Systematic
- Test Direction: Longitudinal- Tensile Test Length: 50 mm
EN/SEW – High Strength Steel
- Focus on Yield Strength
- YS-Steps: 40 MPa
- Test Direction: TransverseTensile Test Length: 80 mm
JFS/JIS – High Strength Steel
- Focus on Tensile Strength
- TS-Steps: Not Systematic
- Test Direction: Transverse- Tensile Test Length: 50 mm (JIS)
EMS.ME – High Strength Steel
- Focus on Yield Strength
- YS-Steps: 40 MPa
- Test Direction: Transverse- Tensile Test Length: 50 mm
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• Global availability of materials• Grade/material commonization• Supplier capability differences• Variability in materials
– Chemistry– Microstructure– Mechanical Properties– Performance
Challenges
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Global Grade Strategy
FOCUS: Guarantee Global Availability of Material
North America
Europe
Asia
BO-GradesHR-Martensitic
Mild SteelB2-GradesDP-Steels
CR180P
CR210PCR240LA
CR180IFTrip-GradesCR MS900
C-Mn
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Global Material Specifications are the Common Engineering Language
Global Specifications
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Basic Structure of GMW´s• Test direction selected as the lowest strength direction
• YS and TS specified for all Advanced HSS‘s
Result: CR 590T/340Y DP (Common name: CR DP600)
Base Material Test DirectionGMW 2: Mild Steel Long. & Transverse DirectionGMW 3032: High Strength Steel Longitudinal DirectionGMW 3399: Multiphase Steel Longitudinal Direction
Globalization – Impact on Steel Industry
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Strategy• Common part design
– One part number valid world wide• One material specification for each part number
– Same material used worldwide• Single validation of a product
– Basic product will be validated once• Common manufacturing process
– One engineering package for all regions.
Requirement: Common materials in each region
Globalization – Impact on Steel Industry
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Globalization – Impact on Steel Industry
Benefit
• Increase engineering and manufacturing efficiency• Leverage global engineering and manufacturing
resources• Reduced product validation• Reduced engineering costs• Eliminate redundant development work• Increased speed to market• Maximize opportunities of global purchasing
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Global Grade Strategy
Catalog of Globally Available Materials
Global Availability
TechnologicalCompetitiveness
Product Engineering Grade Manufacturing Engineering Grade Common Name Bare EG (5) HD/GA Exposed
CR1 x x xCR2 x x xCR3 x x x xCR4 x x x x
CR5 CR5 x x x xHR1 HR1 x xHR2 HR2 x xHR3 HR3 x x
CR180 E see table below x x x x
CR180B2 CR180B2 x x x xCR210B2 CR210B2 x x x xCR240B2 CR240B2 x x xCR270B2 CR270B2 x x x
CR180IF/P CR180IF or CR180P x x xCR210IF/P CR210IF or CR210P x x xCR240IF/P CR240IF or CR240P x x x
CR240LA CR240LA x x xCR270LA CR270LA x x xCR300LA CR300LA x x xCR340LA CR340LA x x xCR380LA CR380LA x x xCR420LA CR420LA x x x
HR270LA HR270LA x xHR340LA HR340LA x xHR420LA HR420LA x xHR550LA HR550LA x x
270LA 3) CR or HR270LA x x x300LA 3) CR or HR300LA x x x340LA 3) CR or HR340LA x x x380LA 3) CR or HR380LA x x x420LA 3) CR or HR420LA x x x
CR490T/290Y DP CR490T/290Y DP CR DP500 x x xCR590T/340Y DP CR590T/340Y DP CR DP600 x x xCR780T/420Y DP CR780T/420Y DP CR DP800 x x xCR980T/550Y DP CR980T/550Y DP CR DP1000 x xCR980T/650Y DP CR980T/650Y DP CR DP1000 High Yield x x
CR900T/700Y MS CR900T/700Y MS CR MS900 x x
HR 1200T/1030Y MS 2) HR 1200T/1030Y MS HR MS1200 x x
HS1300T/950Y MS HS1300T/950Y MS GMW14400 - PHS* x TBD
GMW Grade (1)
CR
Coating (4,6)
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Global Coating Strategy
Canada/USA/MexicoEurope
China
Japan, Korea, AustraliaSouth America
Overview of Common Coatings by Region
GI, GA, EG GI, EG
GI, GA, EG
GAGI, GA
GI: HDG Zinc
GA: Galvanneal
EG: Electro Zn
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Global Coating Strategy
Global Epsilon
Design
Coa
tings
ELPO
Cav
ity w
ax
Seal
ing
Product(corrosion protection)
Coatings: One of the 4 Pillars of Vehicle Corrosion Protection
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Sheet Metal Attributes
Sheet Metal
Product Joining
PaintStamping
Weldability,
Chemistry,
Joining
Process
Crash/FatigueCorrosion
Formability,
Tribology
Paintability, Paint
Appearance
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Status
• Grade Strategy
•Coating Strategy
• Global Standards (GMW‘s)
• Material Strategy
Common
Implementation of Common Strategy
In Process
• Surface Finish
• Strain Rate Properties
• Lubrication
• Carbon Equivalent
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Elo
ngat
ion,
%
Tensile Strength, MPa300 600 900 1200 1500
IF
LC
0
10
20
30
40
50
60
70
IF-HS
BH
C-MnHSLA
DP, CP
TRIP
MART
Low Strength Steels<270 MPa
AHSS’s & Ultra HSS’s Steels >700 MPa
High Strength Steels270-700 MPa
Automotive Steel Strength/Ductility Ladder
PHS
Primary Materials Needing Commonization
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41% Low Carbon
HSLA, 5%
Low Carbon, 12%
* Body Structures Only
Dual Phase , 12%
Solid Solution Strengthened, 5%
Bake Hardenable, 37%
8% Ultra HSS (980 – 1500 MPa TS)
36%, Advanced HSS (490 – 780 MPa TS)
44% Conventional High Strength Steel
(210-420 MPa TS)
Steel Usage Changing
2004 Vehicle 2012 Vehicle
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Dual Phase 980 Example
Grade Version
Coating Type
Tensile Strength, MPa, min
Yield Strength, MPa, min
Total Elongation, %
(typical)
Hole Expansion
GradeA Bare/EG 980 550 ~ 11 NoB Bare/EG 980 650 ~ 13 NoC Bare/EG 980 800 ~ 9 YesD GI/GA 980 600 ~ 14 No
Mechanical Properties
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Chemistry
Dual Phase 980 Example
Grade Version Carbon Mn Si Others CE
A > .12 > 2.0 ~ 1.0 - 1.2 Mo, Cr, B, etc 0.28 - 0.33B > .12 > 2.0 ~ 1.0 - 1.2 Mo, Cr, B, etc 0.28 - 0.33C < 0.10 >> 2.0 < 1.0 Mo, Cr, B, etc 0.20 - 0.25D 0.10 - 0.13 >2 < 1.0 Mo, Cr, B, etc 0.24 - 0.28
CE = C + Mn/20 + Si/30 + 4S + 2P
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Pre-Requisites for Global Body Shop• Common welding performance for “same” grades• Common manufacturing processing windows
Material Requirements
Joining
• Similar welding parameters for the same grades in all regions
Steel industry support of global grades
Strive for similar performance and processing of those grades
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Joining
High Carbon Equivalents Increase Likelihood of Interfacial Fractures
Interfacial Fracture Button Pull-out
CE ~ 0.28 CE ~ 0.20
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0
0.1
0.2
0.3
0.4
Supplier A
Supplier B
Supplier B
Supplier C
Supplier C
Supplier d
Joining
Carbon Equivalent: Variability between suppliers
0
0.1
0.2
0.3
0.4
Suppli
er A
Suppli
er B
Suppli
er B
Suppli
er C
Suppli
er C
Suppli
er d
CR DP800 CR DP1000HDG
EG
HDG
HDGHDG
EGHDG
HDG
EG EG
HDGHDG
Car
bon
Equi
vale
nt
Car
bon
Equi
vale
nt
CE = C + Mn/20 + Si/30 + 4S + 2P HDG – Hot Dip Galvanized, EG - Electrogalvanized
Increasing Likelihood of
Interfacial Fractures
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Product Performance
Effect of boron on DBTT of ULC phosphorus bearing steels
Nominal Chemistry: 0.004%C, 0.25% Mn, 0.06% P
Ductile Fractures
Brittle Fractures
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Product Performance
GMW3032M-ST-S CR300LA is a good match for APFC 390
GMW3032M-ST-S CR270B2 is not a good match for APFC 390APFC 390
270B2 min
270B2 mean
270B2 max
APFC 390
300B2 min
300B2 mean
300B2 max
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• Steel companies and grades will be approved globally and not regionally
• Grades approved by “Global Ferrous Materials and Sheet Metal Team” will be considered acceptable for use in other regions
Level I: Global Engineering Requirements
Level II: Regional Manufacturing Requirements
Level III: Supplier Qualified to Level 1 and Level 2 in all regions
Global Qualification Process
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Conclusion
• Globalization of the steel and automotive industries is following similar paths
• The challenges for both industries are large, but the benefits are also large
• Commonization of material grades, to the extent possible, is critical to the continued globalization of our industries
• Continued cooperation and increased focus will accelerate these changes and benefit everyone