Stainless steel -future lightweight fuel tank. Stefan Schuberth Sr. Manager Krefeld Research Center Outokumpu May 27, 2015

Transcription

1

2 Stainless steel -future lightweight fuel tank Stefan Schuberth Sr. Manager Krefeld Research Center Outokumpu May 27, 2015

3

4

5 Core 4310 (HyTensX) A revolutionary step for the next generation of fuel tanks 15/06/15 5

6 Contents 1. Outokumpu as a partner from development to market 2. Market needs for light weight 3. Fuel tanks today and requirements 4. Stainless steel fuel tank development for hybrid cars and outlook 15/06/15 6

7 Contents 1. Outokumpu as a partner from development to market 2. Market needs for light weight 3. Fuel tanks today and requirements 4. Stainless steel fuel tank development for hybrid cars and outlook 15/06/15 7

8 Material evaluation process at Outokumpu Focus on the customer from the very beginning Material development Laboratory sample Example coil Small series Preseries Series production launch 15/06/15 8

9 Characterization of new materials Testing equipment for automotive needs Tensile testing Forming and shape measurement Spot welding test Stretch forming test Welding tests with robot 15/06/15 9

10 Core 4310 (HyTensX) Technical background Steel grade [EN ] Steel name [EN ] Steel name [ASTM] Producer Melt code Thickness [mm] X 10 CrNi 18-8 Type 301 Outokumpu Ferritic microstructure Austenitic microstructure Austenitic steel with perfect forming abilities and pressure resistance. 15/06/15 10

11 Austenitic and ferritic steels Characterization of forming behaviour 60 mm deep drawing 140 mm plane-strain Round blank stretch forming Major strain Minor strain Metastable austenitic steels have a better stretch forming behaviour than ferritic steels. 15/06/15 11

12 Core 4310 (HyTensX) Forming properties Special requirements for simulation and material laws Rolling direction Ferritic Austenitic ,0 1,6 1,2 0,8 0,4 0 0,4 0,8 1,2 1,6 2,0 r-value 15/06/15 12

13 Contents 1. Outokumpu as a partner from development to market 2. Market needs for light weight 3. Fuel tanks today and requirements 4. Stainless steel fuel tank development for hybrid cars and outlook 15/06/15 13

14 CO 2 footprint of European OEMs Fleet-average weight and fleet-average CO 2 emissions by carmaker compared with 2015 EU target line Average CO 2 - emissions of cars registered in 2012 (g/km) 2015 EU Target: EU Average = 140 g/km Note: Bubble size reflects the size of the CO footprint of the total of cars sold Source: VA Automotive 2013 Average weight of cars registered in 2012 (kg) 2013! 15/06/15 14

15 OEM penalty payments resulting from new emission laws Predicted penalty payment per car manufacturer in Europe in 2015 Source: VA Automotive /06/15 15

16 Sustainability legislation in 2015 and 2020 CO 2 emission targets Source: VA Automotive /06/15 16

17 Contents 1. Outokumpu as a partner from development to market 2. Market needs for light weight 3. Fuel tanks today and requirements 4. Stainless steel fuel tank development for hybrid cars and outlook 15/06/15 17

18 Fuel tanks today Fuel tank materials by region China North America Japan Europe Source: The ITB Group % 20% 40% 60% 80% 100% Plastic Steel 15/06/15 18

19 Fuel tanks today Plastic tanks Typical co-extruded 6-layer structure Material thickness 5-6 mm Plastic tanks are economic only for high production volumes due to high investment costs. Disadvantages: Difficult recyclability, fuel gas emissions, pressure resistance 15/06/15 19

20 Why is stainless steel so interesting today? Today s fuel tank requirements: Legal aspects: New environmental (CO 2 emission) laws (US/ Europe/ China) Mechanical/ cyclic fatigue/ pressure requirements Maximizing volume, minimizing weight Future aspects for tank industry: Hybrid cars need higher pressure resistant tanks because of gas evaporation during battery use. The large variety of car classes and car models leads to smaller tank production volumes. No fuel gas emissions No ageing during lifetime use Recyclability Mercedes C 350 e Plug-in-Hybrid, Source: Auto Bild 15/06/15 20

21 Already existing fuel tanks with Outokumpu Stainless Steel Core 304/4301 Core 304/4301 used since 1990s: No gas emmissions Good formability Further special customer requirements Material thickness 1.2 mm 15/06/15 21

22 Fuel tank development for hybrid cars Core 4310 (HyTensX) Material thickness reduced from 1.2 mm to 0.6 mm Weight cut to half Complex geometries possible Very economic 15/06/15 22

23 Contents 1. Outokumpu as a partner from development to market 2. Market needs for light weight 3. Fuel tanks today and requirements 4. Stainless steel fuel tank development for hybrid cars and outlook 15/06/15 23

24 Fuel tank development for hybrids Saab 9-3 Aero Sedan tank with Core 4310 (HyTensX) Corporate development of Outokumpu and our partner TechROi AB Initial thickness: 0.6 mm Final thickness distribution between 0.45 mm and 0.65 mm 15/06/15 24

25 Advantages of new stainless steel fuel tank Benchmark Core 4310 (HyTensX) against plastic tank Weight: Saved more than 3.0 kg weight! influence on CO 2 emissions and penalties Volume: Gained 3 liters of volume compared to equivalent plastic tank Investments for tools: Reduced by % for volumes of tanks/a Development costs: Engineering costs were reduced by over 50 % (specific for this project) Time to market: Was reduced by approximately 50 % 15/06/15 25

26 Summary and Outlook Projects: Due to new environmental laws many new stainless steel tank projects come up with significant production volumes. o Hybrid or gas tanks have the biggest advantage in regard of weight reduction. o Materials: 80 % of all tanks can be made out of stainless steel when well engineered. Higher strength materials (HyTensX, Forta H500) have advantages over Grade 304 Faster to market: Increasing number of car models leads to the need for shorter development times. Use of stainless steels leads to cutting down time and reuse of equipment. 15/06/15 26

27