ArcelorMittal GDIS 2025 automotive innovation presentation highlights 

Below are brief summaries of each presentation: 

“With some of the best researchers and engineers on the globe, we have developed materials and processes to condense partsand streamlineand tailor solutions that maximize efficiency, affordability, safety and sustainability,” said Ram Iyer. “Simply put, we want to make highly complex things simpler for our automotive partners.” 

MPI uses ArcelorMittal’s Press Hardenable Steels (PHS) and patented Laser-Welded Blank (LWB) technology to streamline manufacturing and reduce assembly complexity by maximizing integration. This modular solution can be applied across all powertrains and can be used to simplify the design and production of the body-in-white, battery pack,and chassis applications.   

“Automakers taking advantage of MPI are realizing less parts, less process, less floor space, less time, less materials, less CO₂and less assembly cost,” added Gagan Tandon. “And they’re not just increasing their bottom line,they’re contributing to a greener environment and improved crash performance and passenger safety.” 

The Laser Welded Blanking process can reduce production scrap by 20% compared to standard designs. In addition to the higher utilization rate, the best-in-class lightweighting potential of the second generation of PHS contributes to further gross weight reduction through thickness reduction. MPI can reduce material consumption by 14% compared to an initial design fully optimized in PHS. 

Recent advancements in finite-element-based manufacturing process simulation have enabled precise analysis of resistance spot welding (RSW) processes, including nugget formation, indentation depth, and defects like voids and liquid metal embrittlement (LME). AbdelbasetMidawi, Senior Engineer and Welding Specialist at ArcelorMittal Global R&D, discussed how this recent study focused on predicting spot weld behavior for 2mm Usibor^® 1500 sheets. By simulating a welding schedule with 2D and 3D-Simufact software, the nugget diameter andproperties,and the heat-affected-zone properties were predicted.A comparison and correlation to measurements from physical welds showed that the simulations accurately captured weld size and load-displacement curves within 5% error.   

This approach enables the study of additional welding conditions such as 3T and 4T stack-ups, the impact of gapsand misalignment. The new research offers the potential to predict and optimizeweld quality and performance in structural components.This will,in turn,improve the reliability and safety performance of automotive structures in crash events. 

ArcelorMittal has been leading work on battery enclosures, a critical piece of the electric vehicle. Battery enclosures serve as a shield to protect cells, electronic systems and cooling systems from external elements and alsoabsorb impact in a crash. Kevin Eldridge and Caroline Kella explained how ArcelorMittal research has not only perfected the strength and durability of the enclosure, but now also have a prototype of anenclosure tray to offer more efficient packaging solutions for OEMs.  

Creating more space is highly valuableand ArcelorMittal’s promising prototype of a stamped tray-based battery enclosure with increased interior volume drew attention from the crowd. By utilizingazero-degree draft angle and a very tight punch, die and corner radii, the presenters shared howautomakers stand to gain from the results of the detailed dimensional analysis.

ArcelorMittal’s Darryl McCaleb, a scientist in advanced stamping in ArcelorMittal’s Global R&D team, participated in a  five-person panel offering perspectives from steel suppliers, Tier 1 and technical consultants on stamping new,advanced high strength steel grades for automotive benefit.  The engaging discussion highlighted opportunities for combining both high strength and complex part shape in stampingas an asset to the automotive market. The panel also discussed some of the challenges and care that should be taken to ensure a safe and successful stamping process with these new grades.   

Of note was ArcelorMittal’s background and experience with new AHSS steel grades, and especially the comprehensive support resources available to automotive customers as these steel grades gain more widespread use in the automotive market.As Darryl McCaleb noted, “ArcelorMittal has an extensive, dedicated team of researchers and engineers committed to working side by side with automotive partners.”  

Representatives from ArcelorMittal Tailored Blanks (AMTB),the world leader in the production of laser welded blanks (LWBs), also presented at GDIS 2025: