Advanced zn-coated steel development and manufacturing technology for automotive weight reduction and safety enhancement

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One of the most effective means of increasing automotive fuel efficiency and, thereby, decreasing harmful emissions is vehicle weight reduction. This can be accomplished by increasing the use of advanced high strength steels (AHSS) for structural components and body closures. Vehicle safety is of paramount importance, for which ultra-high strength (UHSS) press-hardening steels (PHS) are comprising increased proportions of safety-related components. The use of UHSS and AHSS in these critical applications permits the use of thinner sheet steel cross-sections while enhancing passenger safety. However, reducing sheet metal thickness demands enhanced corrosion protection to maintain the structural integrity and meet consumer durability expectations, for which Zn-based coatings applied by the continuous galvanizing (CGL) process is a cost-effective means of achieving this objective. This project will focus on developing the next generation of AHSS - third generation (3G) AHSS - which are more highly alloyed than the present generation of AHSS, but have significantly higher strengths without sacrificing formability. However, the higher alloy contents of 3G AHSS require that they be specifically designed to be compatible with the CGL process to ensure that the desired properties be achieved while allowing for the formation of corrosion protective Zn-based coatings; this is one of the objectives of the CRD. Also, the current generation of PHS are not compatible with Zn-based coatings for corrosion protection and the development of the next generation of Zn-coated PHS is also one of the primary objectives of the CRD. Last, but not least, the processing techniques used to overcome the difficulties of processing AHSS in the CGL can cause problems with the critical spot welding fabrication process. For this reason, the last objective of this CRD is to systematically determine the effect of AHSS processing alternatives on the spot welding process. This project will train ten students for the Canadian automotive and steel industries and will provide the both industries with a set of tools which can be used to increase their competitive advantage in the highly demanding automotive sector.********