EAST CHICAGO | Work done in the region is having a global impact.
Engineers at the ArcelorMittal Global R&D East Chicago helped develop a new range of stronger steels that will allow automakers to cut weight out of cars. They collaborated with another ArcelorMittal research and development team in Maizières-lès-Metz, France, to produce Fortiform, which initially will be manufactured only in Europe.
"We work together with carmakers from the early stages of a vehicle's life to integrate the most innovative steels in their designs," said Greg Ludkovsky, vice president of global R&D at ArcelorMittal. "This enables them to hit targets for fuel efficiency without compromising on safety, style or affordability."
Steelmakers such as ArcelorMittal are engaged in a competition that's been dubbed "car wars" after governments across the globe – most notably the United States and the European Union – imposed tough new tailpipe emissions standards that necessitate shedding weight from vehicles. Aluminum smelters and makers of other alternative metals have since worked to make inroads in the automotive market that's long been dominated by steel. Ford decided to make its new F-150 with an aluminum body, and other automakers are expected to experiment more with lighter and more expensive alternatives than steel, which traditionally has accounted for about 60 percent of a vehicle's weight.
The steel industry – still the heavyweight in the automotive market – has counter-punched with advanced high-strength steels, as well as redesigns of car parts that incorporate tougher, lighter grades.
Two AcrelorMittal mills in Belgium will make ArcelorMittal's new Fortiform metal, which can reduce weight by 10 to 20 percent. Fortiform steel is stronger, meaning less of it can be used in cars, which helps automakers meet stringent new EU emissions standards.
The EU aims to reduce average emissions 18 percent by 2015, and then 40 percent by 2021.
ArcelorMittal's new metal can be used to reduce the amount of carbon dioxide emitted. Using less steel, Fortiform can absorb more energy in crashes, making it ideal for structural parts such as front and rear chassis members.
Samples of the new metals will be offered to automakers for testing this year, before widescale production kicks off next year, spokewoman Mary Beth Holdford said. More advanced high strength steels are still under development.
ArcelorMittal employs more than 1,300 scientists around the globe at facilities such as the R&D center in East Chicago, where they work on improving processes and making new products. The Luxembourg-based steelmaker devoted 30 percent of its $270 million annual research and development budget to the automotive sector, a key customer. Its new Fortiform 1040 has already undergone formability and weldability tests and should start rolling off automaker's assembly lines in 2017.
Fortiform 980 and 1180 grades will be released over the next three years.
"ArcelorMittal is supporting automotive manufacturers as they respond to the challenge of meeting new regulations on emissions and fuel economy," Vice President Brian Aranha said. "Fortiform steel grades combine excellent strength and formability and could lead to weight savings of between 10 and 20 percent in vehicle parts, compared with conventional solutions."