"Material Challenges Facing the Automotive

and Steel Industries from Globalization"

Curt D. Horvath
Technical Fellow
General Motors Corporation

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 The Global Automotive Industry

Globalization
• Producing very large “Global Powerhouses”
• Leveraging global resources to improve
efficiency
• Global sharing of products

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 GM’s Global Footprint
Lansing
Lansing C,
C, MI
PORTUGA Warren,
SPAIN MI
U.K. BELGIUM SWEEDEN GERMANY POLAND HUNGARY
Warren, MI
MI Lansing
Lansing Grand
Grand River,
River, MI
Lansing Metal, MILCars
Lansing Metal, MI Cars Trucks MI
Cars
CAMI-Ingersol,
CAMI-Ingersol,
ONT
ONT
Cars
Eisenach,
Eisenach, Germany
Germany Cars Cars Cars
Detroit-Hamtramck,
Detroit-Hamtramck, MI Bochum, Saab,
Saab, Trollhattan,
Trollhattan, Sweden
Willow Run,
Willow Run,
MI
Lansing Tooling,
&
Orion, Cars
MI
Orion, MI
Oshawa
Oshawa Truck,
Truck, ONT
ONT
Hethel,
Hethel,
England
England
SAAB
Bochum,
Germany
Germany
Sweden
MI Massena
Massena Lansing Tooling, Trollhattan,
MI MI Gothenburg, Trollhattan,

AMT
MI
Lansing
Lansing M,
M, MI
MI
Oshawa,
Oshawa, ONT,
ONT, Canada
Canada Gothenburg,
Sweden
Sweden
Sweden
Sweden Antwerp,
Antwerp, Belgium
Belgium CJSC,
CJSC, Zaporoche,
Zaporoche, Ukraine
UkraineTURKEY
Bay
Bay City,
City, MI
MI AMT South
South Lyon,
Lyon, MI
MI Pontiac,
Pontiac, MI
MI Kaiserslautern,
Renault,
Renault, Batilly, Kaiserslautern,
Janesville
Janesville 11 &
& 3,
3, WI
WI Wixom,
St.
St. Catharines,ONT
Catharines,ONT
Oshawa
Oshawa 11 &
& 2,
2, Ont
Ont France
France
Batilly, Germany
Germany Russelsheim, AvtoVAZ, Togliatti, Russia
Germany AvtoVAZ, Togliatti, Russia
Russelsheim, Germany
Cars
Wixom, MI
MI 1&2
1&2
Saginaw
Saginaw ,, MI
MI 1&2
1&2 Bochum,
Windsor, Kaiserslautern,
Kaiserslautern,Germany Bochum,
Romulus, Flint,
Flint, MI Windsor, ONT
ONT Germany Tychy
Tychy––ISPOL,
ISPOL,
Romulus, MI
MI MI Flint
Flint 11 &
& 3,
3, MI
MI
Germany
Germany Bochum,
Bochum,Germany
Germany Poland Gunsan,
Gunsan, S.
S. Korea
Korea
1#2 1,N&S Flint,
Flint, MI
MI Ellesmere Poland
1#2 1,N&S
Lansing Ellesmere Port,
Port,
Lansing Craft
Craft Center,
Center, MI
Fort
Fort Wayne,
Wayne, ININ Lansing Regional. MI
Lansing Regional. MI STSW,
MI England
England
Soedertaelje, Sweden Aspern,
Soedertaelje, Sweden Aspern,
Australia Bupyeong
Bupyeong 11 &
RUSSIA
& 2,
STSW, MI
MI Grand
Grand Blanc,
Blanc, MI
MI Russelsheim, Russelsheim, Australia 2,
Pontiac,
Pontiac, MI Russelsheim,Germany
Germany Russelsheim, S.Korea
Mishawaka,
Mishawaka, IN
IN Parma,
MI Germany
Germany Gliwice,
Gliwice, Poland
Poland
S.Korea
Trucks
Parma, OH
OH Grand
Grand Rapids,
Rapids,
Ellesmere
Ellesmere Port,
Port, Shenyang,
Shenyang, Gunsan,
Gunsan, S.
S. Changwon, S.
Changwon, S.
Bedford UK Antwert, Belgium Biala
Biala(Bielsko),
(Bielsko), China Korea Korea
Bedford MI UK Antwert, Belgium China Korea Korea
MI Lordstown, OH Poland
Poland
Marion, IN Lordstown, OH Lordstown, OH
Fairfax,
Fairfax, KS
KS
Marion, IN Livonia,
Livonia,
MI
Lordstown, OH IBC,
IBC, Luton,
Luton, UK
UK
Luton,
Luton, England
England
Gliwice, Poland
Gliwice, Poland
Qingdao,
Qingdao,
China
China
Yantai,
Yantai, China
China
Changwon,
Changwon,Korea
Korea JAPAN
Changwon,
Changwon, S.
Korea
Korea
S.
MI Moraine,
Moraine, OH
Fairfax, KS
Fairfax, KS Mansfield,
OH Pittsburgh,
Pittsburgh, PA
PA
Bowling
Bowling Green,
Green, KY
KY
Yantai,
Yantai,
China
China
Boryong,
Boryong,Korea
Korea IZUZU
Bupyeong,
Bupyeong, S.
S. Korea
Korea
Mansfield, Toledo,
Toledo, OH
OH
NUMMI-Fremont,
NUMMI-Fremont, CA CA
OH
OH 1&2
1&2 Linden,
Linden, NJ
NJ Szentgotthard,
Szentgotthard,
Yanati,
Yanati, China
China TRUCKS
Bupyong,
Bupyong,Korea
Korea
Moraine, OH -
Moraine, OH - Strasbourg, Hungary
Hungary
Wilmington, Strasbourg,
Wilmington, DE
Indianapolis,
Indianapolis,
IN
IN
JV
JV
Baltimore,
Baltimore, Tonawanda,
DE France
France Qingdao,
Qingdao, China
China
CHINA
Shanghai,
Shanghai,
China
China
MD Tonawanda, Heuliez,
Heuliez, Cerizay,
Cerizay,
Wentzville,
Wentzville, MOMO
MD NY
NY France
France Steyr, Graz,
Steyr, Graz, Cars
Shanghai,
Shanghai,
China
China
Baltimore, Austria
Wentzville, Doraville,
Doraville, GA Baltimore, MD
MD Azambuja,
Azambuja, Austria Shanghai
Shanghai N&S,
Wentzville, MOMO Parma,
GA
Portugal
N&S,
Parma, OH
OH Portugal China
China
Oklahoma
Oklahoma City,
City, OK
OK
Spring
Doraville,
Doraville, GA
GA Indianapolis,
Indianapolis, IN
IN Zaragoza,
Zaragoza,
Spain
TAIWAN
Spring Hill,
Hill, TN
TN Spain
Silao,
Silao, Mexico
Mexico
Spring
Fredericksburg,
Fredericksburg,
VA
VA
Defiance,
Defiance,
OH
OH
CarsLiuzhou,
Toluca,
Toluca, Mex
Mex Spring Hill,
Hill, TN
TN Valencia, Zaragoza,
Zaragoza, Spain
Spain
Liuzhou,
Silao, China
Silao, Mexico
Mexico Valencia,
Venezuela*
Halol,
Halol, India
India China
Spring
Spring Hill
Hill 11 &
& 2,
2, TN
TN Venezuela* Barcelona,
Ramos Barcelona, Liuzhou,
Liuzhou, China
Ramos Arizpe,
Arizpe, Bogota, Spain China
Mexico
Mexico Shreveport,
Shreveport,
Bogota,
Colombia*
Colombia*
Spain
Bertone, 66 October
October City,
City, Egypt
Hanoi,
Hanoi,
Vietnam
Vietnam
THAILAND 1&2
1&2
Ramos
LA
LA Bertone, Torino,
Torino, Egypt
Ramos Arizpe
Arizpe 11 &
& 2,
2, Mex
Ramos
Mex
Quito,
Quito,
Sao
Sao Caetano
Caetano do
do Sul,
Sul, Brazil
Brazil Italy
Italy
Bekasi
Bekasi Indonesia*
Cars
Ramos Arizpe,
Arizpe, Shreveport,
Shreveport, LA
LA Tunis,
Indonesia*
Mexico
Mexico
Ecuador*
Ecuador* Sao
SaoJosé,
José,Brazil
Brazil Tunis, Tunisia
Tunisia -- Rayong,
Rayong, Thailand
Thailand
CKD
CKD
Silao,
Silao, Mex
Mex Arlington,
Arlington, TX
TX Arica,
Arica, Chile*
Chile*
Sao
Sao Caetano
Caetano do
Brasil
Brasil
do Sul,
Sul,
Nairobi,
Rayong,
Rayong,
Thailand
AUSTRALIA
Lagos,
Lagos, Nigeria
Nigeria -- Nairobi, Kenya
Kenya -- Thailand
Toluca,
Toluca, Mexico
1&2
1&2
Mexico
Sao
Sao Jose
Jose dos
Brasil
Brasil
dos Campos,
Campos, CKD
CKD
CKD
CKD
Elizabeth,
Holden Cars
Elizabeth,
Gravatai, Australia
Australia
Gravatai, Brasil
Brasil

Rosario,
Rosario, Argentina Gravatai,
GM
GM South
South Africa
Africa 22 PortINDONESIA
PortMelbourne,
Melbourne,
Argentina Gravatai, Brazil
Brazil Elizabeth,
Elizabeth, South
South Australia
Australia
Australia
Australia
Mogi
Mogi das
das Cruzes,
Cruzes, Rosario, Sao Jose
Argentina Sao
Rosario, Argentina Jose dos
dos Campos,
Campos, GM
GM South
South Africa
Africa 11
Cars & Trucks
Brasil
Brasil Brazil
Brazil
Rosario,
Rosario,
Argentina
Argentina

• Assembly Locations in Over 32 Countries • Annual Volume of 9.1 Million Vehicles

• Products Sold in 170 Countries

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 The Global Automotive Industry

Enablers for Resource Leveraging

• Common vehicle development process

• Common engineering process

• Common manufacturing process

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 The Global Automotive Industry

Common Materials and Specifications……

• Primary Building Blocks for Commonization

• Provide a global, common “language” for

requirements
• Enabler for common engineering and
manufacturing processes

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 The Global Automotive Industry
Global Specifications – Benefits
• Reduce development, manufacturing and
validation costs

• Assist in moving into developing markets

• Improved productivity

• Improved quality

• Enabler for global architectures

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 Complex Material Landscape

SAE/ASTM – High Strength Steel EN/SEW – High Strength Steel

- Focus on Yield Strength - Focus on Yield Strength
- YS-Steps: Not Systematic - YS-Steps: 40 MPa
- Test Direction: Longitudinal - Test Direction: Transverse
- Tensile Test Length: 50 mm (ASTM/JIS) Tensile Test Length: 80 mm (DIN)

JFS/JIS – High Strength Steel

- Focus on Tensile Strength
EMS.ME – High Strength Steel - TS-Steps: Not Systematic
- Focus on Yield Strength - Test Direction: Transverse
- YS-Steps: 40 MPa - Tensile Test Length: 50 mm (JIS)
- Test Direction: Transverse
- Tensile Test Length: 50 mm (ASTM)

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 Challenges

• Global availability of materials

• Material and grade commonization

• Supplier capability differences

• Variability in material
¾Chemistry
¾ Microstructure
¾ Mechanical Properties
¾ Performance

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 Global Grade Strategy
Europe
BO-Grades
HR-Martensitic
North
CR180IF
America CR MS900
Mild Steel Trip-Grades
BH2-Grades Asia
DP-Steels
CR180P
C-Mn
CR210P
CR240LA

FOCUS: Guarantee Global Availability of Material

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 Global Specifications
Global Material Specifications are the Common
Engineering Language

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 Globalization – Impact on Steel Industry
Strategy

• Common part designs

• One material specification for each part number
• Same material used worldwide
• Single validation of a product
• Basic product validated once
• Common manufacturing process
• One engineering package for all regions

Requirement: Common materials in each region

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 Globalization – Impact on Steel Industry

Shared Benefits
• Increase engineering and manufacturing efficiency
• Leverage global engineering and manufacturing
resources
• Reduce product validation
• Reduce engineering costs
• Eliminate redundant development work
• Increase speed to market
• Maximize opportunities of global purchasing

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 Steel Industry Consolidations
HOE + KRU + THY =
TKS
Hog + BSC = Severstahl + Rouge Steel =

CORUS Severstal N.A.

ISG (Bethlehem + LTV) + Dofasco + Ispat = ARC+SID+USI =
MITTAL ARCELOR
U.S. Steel + National =
U.S. Steel

Steel Industry Consolidations are Nippon

Consistent With
CSN Globalization of
Kobe
the Automotive
Usiminas Industry
Merger & Acquisition
Joint Ventures/Technical Collaboration

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 Critical Sheet Metal Attributes

Product i t y, Joining
l
a bi ry,
Cr t
ash eld mis g
Co / Fa W he in
rro tigu C o i n es s
sio e J oc
n Pr

Sheet
Metal
y, Pa
i t int
abil gy a
Ap Pai bilit
orm olo pe nt y,
F rib ar a
T nce
Stamping Paint

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 Global Grade Strategy
Catalog of Globally Available Materials

GMW Grade (1) Coating (4,6)

Manufacturing
Product Engineering Grade Common Name Bare EG (5) HD/GA Exposed
Engineering Grade
CR1 x x x
CR CR2 x x x
CR3 x x x x
CR4 x x x x
CR5 CR5 x x x x
HR1 HR1 x x
HR2 HR2 x x
HR3 HR3 x x

CR180 E see table below x x x x

CR180B2 CR180B2 x x x x
CR210B2 CR210B2 x x x x
CR240B2 CR240B2 x x x
CR270B2 CR270B2 x x x

CR180IF/P CR180IF or CR180P x x x

CR210IF/P CR210IF or CR210P x x x
CR240IF/P CR240IF or CR240P x x x

CR240LA CR240LA x x x
CR270LA CR270LA x x x
CR300LA CR300LA x x x
CR340LA CR340LA x x x
CR380LA CR380LA x x x
CR420LA CR420LA x x x

HR270LA HR270LA x x
HR340LA HR340LA x x
HR420LA HR420LA x x
HR550LA HR550LA x x
3)
270LA CR or HR270LA x x x

Global
3)
300LA CR or HR300LA x x x

Technological
3)
340LA CR or HR340LA x x x
3)
380LA 3) CR or HR380LA x x x
420LA CR or HR420LA x x x

Availability
CR490T/290Y DP CR490T/290Y DP CR DP500 x x x

Competitiveness
CR590T/340Y DP CR590T/340Y DP CR DP600 x x x
CR780T/420Y DP CR780T/420Y DP CR DP800 x x x
CR980T/550Y DP CR980T/550Y DP CR DP1000 x x
CR980T/650Y DP CR980T/650Y DP CR DP1000 High Yield x x

CR900T/700Y MS CR900T/700Y MS CR MS900 x x

2)
HR 1200T/1030Y MS HR 1200T/1030Y MS HR MS1200 x x

HS1300T/950Y MS HS1300T/950Y MS GMW14400 - PHS* x TBD

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Global Coating Strategy
Coatings: One of the 4 Pillars of
Vehicle Corrosion Protection
Product
Global Epsilon

(corrosion protection)

Cavity wax
Coatings

Sealing
ELPO

Design

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 Global Coating Strategy
Overview of Common Coatings by Region

Europe
Canada/USA/Mexico
GI, EG
GI, GA, EG China
GI, GA, EG

Japan, Korea, Australia

South America
GI: HDG Zinc
GA
GA: Galvanneal GI, GA
EG: Electro Zn

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 Global Material Strategy

Many Factors Need Consideration

• Global Standards (GMW‘s) • Phosphateability

• Material Strategy • Strain Rate Properties

• Grade Strategy • Lubrication

• Coating Strategy • Carbon Equivalent

• Surface Finish • Adhesive Bondability

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 Steel Usage Changing
2004 Vehicle 2012 Vehicle

36%, Advanced HSS 8% Ultra HSS

Dual Phase , 12% (980 – 1500 MPa TS)
41% Low Carbon (490 – 780 MPa TS)

Low Carbon, 12%

HSLA, 5%
Solid Solution Strengthened, 5%
44% Conventional High
Bake Hardenable, 37% Strength Steel
(210-420 MPa TS)
* Body Structures Only

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 Dual Phase 980 Example
Mechanical Properties

Tensile Yield Total Hole

Grade Coating Strength, Strength, Elongation, % Expansion
Version Type MPa, min MPa, min (typical) Grade
A Bare/EG 980 550 ~ 11 No
B Bare/EG 980 650 ~ 13 No
C Bare/EG 980 800 ~9 Yes
D GI/GA 980 600 ~ 14 No

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Product Performance

GMW3032M-ST-S CR270B2 is
APFC 390
not a good match for APFC 390
270B2 min
270B2 mean
270B2 max

APFC 390 GMW3032M-ST-S CR300LA is

300B2 min a good match for APFC 390
300B2 mean
300B2 max

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 Joining
Pre-Requisites for Global Body Shop
• Common welding performance for “same” grades
• Common manufacturing process windows

Material Requirements
• Similar welding parameters for the same grades in all
regions
¾ Steel industry support of global grades
¾ Strive for similar performance and processability of
grades

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 Dual Phase 980 Example
Chemistry

Grade
Version Carbon Mn Si Others CE
A > .12 > 2.0 ~ 1.0 - 1.2 Mo, Cr, B, etc 0.28 - 0.33
B > .12 > 2.0 ~ 1.0 - 1.2 Mo, Cr, B, etc 0.28 - 0.33
C < 0.10 >> 2.0 < 1.0 Mo, Cr, B, etc 0.20 - 0.25
D 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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 Joining
High Carbon Equivalents Increase Likelihood
of Interfacial Fractures

Interfacial Fracture Spot Weld

Through Spot Weld Button Pull-out

CE ~ 0.28 CE ~ 0.20
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 Joining
Increasing
0.4 Likelihood of 0.4
Interfacial
CR DP800 Fractures
HDG
CR DP1000 HDG
HDG HDG
HDG 0.3 HDG HDG
0.3 HDG
EG
Carbon Equivalent

Carbon Equivalent
EG EG
EG

0.2 0.2

0.1 0.1

0 0

d
rA

rB

rB

rC

rC

rd

r
ie

ie

ie

ie

ie

ie
lie

lie

lie

lie
lie

lie

pl

pl

pl

pl

pl

pl
pp

pp

pp

pp

pp

pp

up

up

up

up

up

up
Su

Su

Su

Su

Su

Su

S
Carbon Equivalent: Variability between suppliers

CE = C + Mn/20 + Si/30 + 4S + 2P HDG – Hot Dip Galvanized, EG - Electrogalvanized

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 Product Performance
0
Nominal Chemistry: 0.004%C, 0.25% Mn, 0.06% P

-20
Temperature, oC

Ductile
Fractures
-40

-60 Brittle
Fractures

0 5 10 15
Boron Concentration, ppm

Effect of Boron on DBTT of ULC Phosphorus Bearing Steels

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 Global Qualification Process
• 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

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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

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 Acknowledgements

• Michael Rupp, MEP, GM Eurpoe

• Chris Chen, CCRW, GM North America
• Kathy Wang, CAE, GM North America
• Global Ferrous and Sheet Metals Team

Contact: curt.d.horvath@gm.com

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