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Global Steel Industry Developing Vehicle Concept Around Next Generation Electrics, Hybrids

As worldwide demands for affordable, safe and high-efficiency vehicles surge, the global steel industry’s WorldAutoSteel automotive group, supported by AISI’s Steel Market Development Institute (SMDI), is launching Phase 2 of its Future Steel Vehicle (FSV) project. FSV is aimed at helping automakers optimize new propulsion technologies that will soon enter show rooms.

The FSV program recently completed Phase 1 of its research during which its technical team considered four technical specification options for proposed 2015 to 2020 model year vehicles: battery electric (BEV) and plug-in hybrid-electric vehicles (PHEV) for four or more passengers; and PHEV and fuel cell vehicles (FCV) for five passengers. Each of these options was evaluated by the engineering team. Powertrains were selected based on performance, viability for production in 2020, and cost. Two vehicle classes were identified. In Phase 2, the purpose will be to develop detailed design concepts and fully optimize a radically different body structure for the FSV-1 BEV. It will also identify structure changes to accommodate the other three vehicles and powertrain variants.

Aggressive weight-reduction targets have been set for FSV Phase 2. The FSV team intends to meet these targets using engineering design optimization and advanced steel technologies. Achievement of such aggressive weight reduction with steel will set a new standard for vehicle design approaches for the future.

The FSV Phase 2 development will consider a total life cycle assessment of the concept designs to meet CO₂ emissions targets. Regulations that consider only the vehicle use phase can encourage the use of low-density, greenhouse gas (GHG)-intensive materials that provide lighter weight components. However, this may have the unexpected result of increasing GHG emissions during the vehicle’s total life cycle.

WorldAutoSteel and its global engineering partners will develop FSV Phase 2 (Concept Designs) through 2009 and 2010, followed by a demonstration hardware phase. For additional information, visit www.autosteel.org/futuresteelvehicle or contact Ron Krupitzer.