Novel 1.9GPa Tensile Strength Steel for Chain Die Forming of Variable Cross Section

• Electric vehicle structural development is currently focusing on optimizing mass and range, with challenges stemming from the mass of the battery and its need for intrusion protection in a crash. Current roll forming technology, often used in the formation of protective rails and cross members in battery structures, are limited to 1700MS grades and a single, uniform cross section. This can lead to bulky and cumbersome designs to achieve protection of the battery pack and increases mass within the structure. To combat this, we explore a combination of an novel cold formable steel with a maximum ultimate tensile strength of 1.9GPa formed using chain die forming as a proof of concept work. Between the steel's innovative composition, which enables superior shape control during coil processing, and the chain die forming method, we were able to manufacture variable cross section door beams using the new material and process combination. This presentation will explore the steel making process which ensures a flat, cold formable coil and the chain die forming process which manufactures a variable cross section part.