RESEARCH NEWS
AHSS steels for sustainable transport concept
The Steel E-Motive project , a collaboration between WorldAutoSteel ( the automotive group of the World Steel Association ) and Ricardo , demonstrates the suitability of the latest advanced highstrength steel ( AHSS ) grades for use in fully autonomous electric vehicles , engineered for a mobility- as-a-service ( MaaS ) transport model .
WorldAutoSteel steel experts and Ricardo ’ s engineering and environmental experts are working together to develop two vehicle concepts : a smaller four-passenger “ SEM1 ” variant is intended for inner-city journeys and a larger six-passenger variant ( SEM2 ) intended for longer inter-city journeys .
“ The AHSS steel concepts are expected to be finalised in early 2023 and will serve as the basis for car manufacturers in their quest to design sustainable autonomous electric vehicles using AHSS . Autonomous vehicles operating in a ride-sharing MaaS model alongside other public transport will help meet the challenge of serving a growing global population , while providing a sustainable transport solution around and between cities . MaaS vehicles can bridge the gap in urban commuting , providing services such as lastmile transport or filling a need in transportation deserts ,” commented WorldAutoSteel .
Both the smaller SEM1 and larger SEM2 Steel E-Motive vehicles are ‘ all electric ’ with
Sheet-metal defect prediction
The FormPlanet EU-funded project has developed and optimised a set of new advanced methodologies for characterising and modelling metallic materials to predict the appearance of defects , such as cracks , and foresee part performance from the component design phase . The novel methodologies will be launched to the market as services of a commercial entity to be created with the mission to respond to the challenges of the sector .
By using FormPlanet methods , companies will be able to “ adjust the amount of material needed and reduce costs , increase productivity , improve product quality , optimise processes and reduce the time to market for new metallic products ,” explained FormPlanet project technical coordinator , Begoña Casas . “ Our techniques also help to reduce the amount of rejected material due to the appearance of cracks and , consequently , impact positively on the environment ,” she added .
“ Fifteen companies in the European sheetmetalforming value chain have validated the efficiency and reliability of the techniques developed or optimised during the project and proved how to address industrial challenges from alternative approaches ,” stated the coordinator of the FormPlanet project and project manager at Eurecat , Eduard Piqueras .
Application of the methodologies has
The Steel E-Motive programme is working to develop two vehicle concepts for MaaS applications .
allowed participating companies to optimise the production of advanced high-strength steels ; aluminium alloys ; multilayer materials or cold-rolled steels , as well as to predict component formability and in-service performance .
The project , funded by the European Union ’ s Horizon 2020 programme , is a consortium made up of three research centres ( Eurecat , the project coordinator ; Fraunhofer IWU and COMTES FHT AS ); two universities ( Lulea University of Technology and University of Pisa ); three companies ( LETOMEC , Ansys and Applus + Laboratories ); eight industrial enterprises ( CRF – Stellantis , ArcelorMittal , Arania , Estamp , Arcelik , ALUDIUM , AP & T and Lamera ) and UNE as the Spanish standardisation association . n
https :// formplanetproject . eu / zero tailpipe emissions that will help to cut urban pollution . The aim is that the electricity source used for charging will be largely renewable ( e . g . wind , solar ). The vehicles are being designed to be as environmentally friendly as possible during their total lifecycles .
“ The Steel E-Motive vehicles are engineered to minimise greenhouse gas emissions created during vehicle manufacture , achieving more efficient use per part , meaning less overall steel production . This will reduce the greenhouse gas emissions generated during the vehicle ’ s lifetime , from manufacture to endof-life recycling ,” added WorldAutoSteel .
The AHSS body structures are designed to reduce noise and vibration , so that the journey is more comfortable . Steel E-Motive vehicles are also engineered to meet high-speed international crash test standards . n
Aluminium carbonfibre hybrid structures
New aluminium alloys ( AA6xxx ) have recently been developed that have high strength and toughness , low weight and can be manufactured by affordable , energy-efficient means .
“ These lightweight materials offer the potential to revolutionise extrusion-intensive vehicle structures in the automotive sector . This is by substantially reducing material input to component production ; decreasing production time and cost ; and increasing formed product performance over traditional alternatives ( by exploiting novel casting , extrusion , forming and joining technology as manufacturing techniques ),” commented Brunel University in the UK .
In support of these aims , the university aims to conduct a programme to provide formed extruded sections suitable for the manufacture of vehicle frames utilising the new AA6xxx alloys under the name of ‘ Aluminium Carbon Fibre Hybrid Structures ( CAAHS )’.
“ Today , these hollow , tubular components are manufactured from mild steel . This provides an opportunity to replace these components with aluminium alloys of similar and / or higher strengths to achieve weight savings . These weight savings are in the order of 30 % for the baseline welded frame and up to 40 % for the advanced frame fabricated from stronger alloys and using joining
READ technologies , where there is no loss of alloy strength ,” added the university . n
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