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Global WorldAutoSteel Project Presents Interim Results of FutureSteelVehicle (FSV) Phase 2 Project for Low GHG Body Structure for Electrified Vehicles

WorldAutoSteel,the automotive group of the World Steel Association, has presented findings on the progress of FutureSteelVehicle (FSV) Phase 2, a global steel industry effort to develop advanced high-strength steel (AHSS) architectures for electrified vehicles that reduce life cycle greenhouse gas (GHG) emissions.

The FSV Program is midway through its second phase, designing optimized AHSS body structures for four proposed 2015-2020 year vehicles: battery electric (BEV); plug-in hybrid electric (PHEV), with both PHEV-20 and PHEV-40 powertrains; and fuel cell (FCV), with variants among the different powertrain types for four and five passengers vehicles.

The interim results presented at GDIS by the engineering team at the North American automotive conference “Great Designs in Steel (GDIS),” convened by the American Iron and Steel Institute (AISI), made reference to the optimization of multiple solutions for seven different sub-systems:

  • The rocker;
  • B-pillar;
  • Roof;
  • Rear and front rails;
  • Front upper load path; and
  • Battery tunnel load path members

General results included:

  • New benchmark in weight reduction achieved through Advanced High-Strength Steel optimized structures, enabling powertrain downsizing for affordable electrified vehicles.
  • Portfolio of innovative steel solutions that apply to full range of electrified or internal combustion engine vehicles.
  • New design methodology to realize the best environmental solution for compliance with future vehicle emission regulations.
  • CO2 emissions, measured through a life cycle assessment, reduced in the seven optimized sub-system structures, at lower or comparable costs.

FutureSteelVehicle offers design solutions that can apply to any vehicle, whether for electrified or conventional internal combustion engine (ICE) vehicles. Because of steel’s flexibility, we were able to produce a broad bandwidth of solutions, all of which were evaluated on the basis of cost versus weight and CO2 equivalent emissions. Within this portfolio of solutions are applications that all vehicle manufacturers and segments will find relevant.

Key to our Phase 2 evaluations of different structural options is a life cycle assessment of each system based on the University of California at Santa Barbara (UCSB) GHG Materials Comparison Model. FSV stretches emissions targets out in anticipation of future legislation and requirements around the world.

—Jody Shaw, Chairman, FSV Program and manager of Technical Marketing and Product Research at United States Steel Corporation

FutureSteelVehicle is achieving its results through the use of a broad range of available steel grades and a design optimization process that develops non-intuitive solutions for structural performance, including optimized shapes and component configurations. FSV’s steel portfolio is utilized during the material selection process with the aid of full vehicle analysis to determine material grade and thickness optimization.

Over the next months, WorldAutoSteel members will disseminate these FSV technical results directly to automakers around the globe, sharing the sub-system optimization methodology and findings on a global basis and gathering feedback that will be integrated into the program scope.

In the meantime, the FSV Phase 2 engineering work will continue to advance to the design of complete body structures, with an engineering report and final results made public in early 2011.

Members of WorldAutoSteel are:

  • Anshan Iron and Steel Group Corporation – China
  • Arcelor Mittal - Luxembourg
  • Baoshan Iron & Steel Co. Ltd. - China
  • China Steel Corporation – Taiwan, China
  • Hyundai-Steel Company - South Korea
  • JFE Steel Corporation - Japan
  • Kobe Steel, Ltd. - Japan
  • Nippon Steel Corporation - Japan
  • Nucor Corporation – USA
  • POSCO - South Korea
  • SeverStal - Russia/USA
  • Sumitomo Metal Industries, Ltd. - Japan
  • Tata Steel & Corus - India, UK, Netherlands
  • ThyssenKrupp Stahl AG - Germany
  • United States Steel Corporation – USA
  • Usinas Siderúrgicas de Minas Gerais S.A. - Brazil
  • voestalpine Stahl GmbH – Austria



Not surprised to see that the steel industry is defending its own interest with potential improvements, specially when strong poly-plastics and carbon fiber are starting to move in for future lighter e-vehicles.

May the best product (for informed users) win.


I have invented a way to make small cars safer in collisions.
It will allow auto makers to make their cars lighter to help meet the new CAFE fuel economy rules.
It will also help auto makers meet the new NHTSA side impact into a pole test.

Electric vehicle range is very sensitive to vehicle weight, and my invention can enable substantial weight reduction. Less steel will be needed to protect passengers.


The invention has been granted US patents 7,695,018 and
Please help me promote this invention that can save fuel and lives.

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