Steel E-Motive’s: smart, sustainable steel solutions for autonomous vehicles

ArcelorMittal and its partners continue to drive innovation in automotive manufacturing. The Steel E-Motive programme, an ambitious initiative by WorldAutoSteel, aims to revolutionise future mobility through autonomy and sustainability thanks to smart steel and ArcelorMittal Multi Part Integration^® solutions.

One of the significant achievements of the Steel E-Motive programme is its utilisation of Advanced High Strength Steel (AHSS) innovations. Seven new AHSS applications have been developed to deliver a safe, efficient, and affordable structure.

Undertaken by the Ricardo engineering company, in partnership with WorldAutoSteel, a global association of 17 steel companies including ArcelorMittal, this programme has engineered innovative vehicle and body structure concepts. The travel experience is optimised through a spacious interior, while keeping to the lowest possible footprint to limit city congestion. The Steel E-Motive concept demonstrates exceptional protection of occupants and battery, fulfilling all high-speed crash requirements.

The Steel E-Motive programme incorporates various advanced features that ensure high levels of occupant comfort and accessibility, competitive weight, cost-effective design, and suitability for global high-volume production. This exceptional performance has been achieved through innovative designs and the use of a high proportion of Press Hardening Steels (PHS) (33%) and MartINsite^® grades (16%).

Without a driver cockpit, the large interior space allows passengers to face each other, improving the sense of roominess and ride comfort. This innovative design has pushed the safety structure to the vehicle’s edge, resulting in a short front structure while still meeting high-speed crash safety requirements. These achievements were made possible through the use of a PHS-intensive design with 1500 MPa steel grade, such as ArcelorMittal’s Usibor^®1500.

Steel E-Motive’s B-pillarless one-box open body structure provides a wider door aperture for easy access and cargo use.

The lateral structure features a large laser-welded blank Press Hardened Steel Door Ring, known as an ArcelorMittal Multi Part Integration^® (MPI) solution. The Door Ring is tailored in grades and thicknesses to put the right material in the right place. Strong 2000 MPa material is used on the A-pillar, such as ArcelorMittal’s Usibor^®2000, to withstand frontal loads. Ductile material like Ductibor^®1000 is used on the middle section to absorb energy in lateral pole crashes and to protect the battery. 1500 MPa material, such as Usibor^®1500, is used on the C-pillar to ensure good passenger protection in lateral crashes.

The Steel E-Motive programme achieves part integration by replacing four parts with one for the side structure, reducing weight by removing flange overlaps, and simplifying assembly by reducing weld points. This innovative approach leads to a more efficient structure with minimal footprint, aligning with the programme's sustainability and efficiency goals.

Thanks to advanced steel solutions, the vehicle meets all high-speed crash requirements, ensuring the safety of occupants and the protection of the battery.

Steel E-Motive offers a clear path to net-zero emissions. Solutions can be Plug & Play. The Steel E-Motive programme not only focuses on advancing autonomous mobility solutions but also underscores the commitment to environmental responsibility, through reduced weight and improved vehicle performance - the programme plays its part in the journey towards sustainable automotive manufacturing.

In summary, the Steel E-Motive programme is a prime example of how collaborative efforts in the steel and automotive industries can lead to groundbreaking advancements. With its emphasis on safety, efficiency, and sustainability, the programme is set to revolutionise the future of mobility, demonstrating that the integration of advanced steel solutions can lead to a more sustainable and autonomous future. As the programme continues to develop and innovate, it will undoubtedly contribute significantly to the global push for more sustainable and more efficient transportation solutions.

Through these concerted efforts, ArcelorMittal and its partners are not only addressing current challenges but also paving the way for future innovations in the automotive sector. The Steel E-Motive programme is a testament to what can be achieved when industry leaders come together with a common goal of creating a smarter, safer, and more sustainable world.