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International Journal of Emerging Technology and Advanced Engineering

Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 6, Issue 7, July 2016)

Application of Steel in Automotive Industry


Mayank Kumar Singh
Student, B.Tech (Automobile Engineering), Manipal Institute of Technology, Manipal
Abstract— Over the years, steel has remained the key In the recent past, there has been increasingly use of
materials in the automotive industry. Steel has wide range of high-strength steels (HSS), which may also be referred to
yield strength with high modulus of elasticity. Steel is also as high-strength, low-alloy (HSLA) steels. Series of studies
considered as most preferable material in automotive conducted by American Iron and Steel Institute (AISI)
application due to low cost. Other benefits of steel include
Ultralight Steel Auto Body (ULSAB) demonstrated
light weighting opportunities using new generation high
strength steel leading to fuel efficiency, enhanced safety, good improved design and 19% mass reduction in a body
recyclability, and formability characteristics. This paper structure that had superior strength and structural
discusses the current trend, application and recent progress in performance (including crashworthiness) along with a
usage of various types of steel in automobile sector. Recent reduced parts count and net manufacturing cost savings
development of next generation steel such as Advanced High compared to a conventional steel body [2]. Similar benefits
Strength Steel (AHSS) has also been elaborated. in terms of mass reductions were achieved for doors,
hoods, deck lids, and hatchbacks [3]. These materials
Keywords—Steel, Automotive, Industry, Advanced High
further led to improved application and better forming
Strength Steel, Material
processes allowing a significant optimization of vehicle
body structures and components [1]. Iron and steel industry
I. INTRODUCTION
has embedded their research activity to address new
Over the years, steel has remained the key materials in designs and redesigns requirements of automotive
the automotive industry. Steel has also established as manufacturers. The steel industry and component suppliers
reasonable in cost, longer life and variability in strength are investing heavily in innovation.
levels while meeting the increasingly stringent engineering
needs. Steel is also very adaptable to corrective rework. II. DRIVERS OF STEEL APPLICATION
Moreover, this material has exceptional versatility in terms
Recent drivers of steel application in automotive sector
of formability and the industry has also responded quickly
include cost, fuel efficiency, regulatory requirements,
to recognize the changing due to legislative and
safety, recyclability, light weighting, formability and
environmental requirements. Some of the other advantages
specific customer requirements. Automotive companies
of steel with respect to be used in automotive sector are
consider all these factors in their design and maintain an
ease of forming, consistency of supply, corrosion resistance
optimized and balanced solution.
with zinc coatings, ease of joining, recyclability and good
crash energy absorption. Some of the disadvantages are that A. Cost
steel is considered as heavier than its competitive materials Cost is one of the most important driving factors for
and gets corroded very easily if uncoated. There have been selection of material in automotive sector. Normally cost
significant developments in producing wide range of steel includes major components such as cost to design, cost of
using various additives and deploying technological raw materials, manufacturing cost and cost of testing the
interventions during steel production. product. Other key variables include manufacturing cycle
Steel is considered as vital material in the majority of times, better machinability, ability to have thinner and
vehicles. There has been development of new formulation more variable wall dimensions, closer dimensional
of steel chemistry producing high-strength steels. This tolerances, reduced number of assemblies, more easily
requires further attention on giving focus on new design, produced to near net shape(thus decreasing finishing costs,
fabrication, and assembly techniques by automotive and less costly melting/metal-forming processes) [4].
companies. As applications of steel is not only in vehicle
bodies, but also engine, chassis, wheels and many other B. Lightweight
parts and components aiming further to demonstrate weight Weight reduction is considered a key criterion for
reduction, enhanced fuel efficiency and simultaneous reducing fuel consumption and greenhouse gases from the
improvements in strength, stiffness, and other structural transportation sector.
performance characteristics [1].

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International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 6, Issue 7, July 2016)
It has been estimated that for every 10% of weight Steel is considered to be most recycled material in the
eliminated from a vehicle's total weight, fuel economy world with high level of recycling efficiency. Polymers
improves by 7% and reduction of 5% GHG emission mixed with composites have major challenges recycling
achieved [10]. and recoverability. Considerable R&D efforts are now
All automotive manufacturers along with their suppliers focused on developing materials with greater potential of
are investing significantly in development of lightweight recycling and re-use or developing ways of recycling and
materials. The major challenge associated with lightweight re-use of the current materials.
materials is their high cost. Priority is given to activities to
reduce costs through development of new materials, III. MATERIAL PROPERTIES AND PERFORMANCE
forming technologies, and manufacturing processes while Before choosing a material for design there are three
maintaining the same rigidity [4]. main factors to be looked upon. Material performance
C. Safety, crashworthiness (density, tensile strength, modulus, corrosion resistance,
There are two key safety concepts to consider viz. elongation, cost, availability, environment considerations,
crashworthiness and penetration resistance. performance, manufacturability), Government regulations
Crashworthiness is defined as the potential of absorption of (fuel efficiency, light weighting, crash performance,
energy through controlled failure modes and mechanisms emissions), Customer requirements (cost, quality features).
that provides a gradual decay in the load profile during The basic criteria a material should also satisfy are
absorption while penetration resistance is concerned with structural dynamics, static stiffness, weight optimization,
the total absorption without allowing projectile or fragment crashworthiness.
penetration [4]. Steel is having excellent performance in terms of yield
Steel is considered to be one of the best energy and tensile strength, elongation to fracture, anisotropy and
absorbent materials. The absorption energy is calculated Young’s modulus. The strength of a component that should
based on the area covered under the stress-strain curves. be under axial loading is related to the mechanical
High strength steel provides better performance in crash properties of the material [7].In bending and torsion, both
due to higher work hardening rate and high flow stress. material and shape are important parameters for the
This will result in more uniform strain distribution in steel efficiency of the component to carry the applied load [8].
material in the crash event. Some of the important aspects For bending, the elastic-plastic transition is a combination
are considered in design for better crashworthiness include of shape and material properties. The following key
geometrical and dimensional aspects, materials characteristics should be considered for proper material
deformation, progressive failure behaviour in terms of selection:
stiffness, yield, strain hardening, elongation and strain at A. Stiffness
break of the vehicle. [5]. Modulus of elasticity (E) and geometry of material have
D. Recycling and End of vehicle life considerations direct linkage with stiffness of a component. As E value
There have been key trends about developing the has been constant for all steel grades, so geometry can only
environment friendly vehicles with focus on conservation be changed to improve stiffness. Steel provides excellent
of resources, reduction of CO2 emissions, increasing the flexibility due to its higher formability for optimizing the
fuel efficiency during vehicle usage life time and stiffness. For high strength steel reduction in gauge can be
subsequently enhanced recycling and recovery of materials counterbalanced by changes in geometry or by using
at the end of vehicle life [6]. continuous joining techniques such as laser welding or
For achieving higher recoverability and recyclability of adhesive bonding [4].
vehicle at its end of life, there are already regulations B. Strength
existing in EU, Japan, South Korea etc. India has also come Strength of a component is primarily dependent on yield
up with draft standards on the same. The End of Life strength, tensile strength and geometry of component. Steel
Vehicles (ELV) Directive aims to reduce the amount of offers design flexibility over other materials due to their
waste produced from vehicles when they are scrapped. It higher formability and work hardening characteristics.
also sets higher reuse, recycling and recovery targets and High strength steel grades also have good bake hardening
limits the use of hazardous substances in both new vehicles ability [9].
and replacement vehicle parts [6].

247
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 6, Issue 7, July 2016)
C. Fatigue Another classification method is based on yield strength
Fatigue properties of automotive components depend on range as all the steel grades are having same density and
geometry, thickness, applied loads and material endurance elastic modulus. Steel having yield strength less than 210
limit. The endurance limit of a material increases with MPa are considered as conventional steel. High-Strength
tensile strength. Thus, high strength combined with Steels (HSS) has yield strengths from 210 to 550 MPa and
superior work hardening and bake hardening, resulting in a tensile strengths from 270–700 MPa, while Ultra/Advanced
significant increase in the as-manufactured strength of high High Strength Steels (UHSS or AHSS) steels have yield
strength steel components, also results in a better fatigue strengths greater than 550 MPa and tensile strengths greater
resistance [9]. than 700 MPa [9]. In addition, many steel types have a
wide range of grades covering two or more strength ranges.
D. Formability Third type of classification is based on the mechanical
Steel has many advantageous characteristics connected properties or forming parameters of different steels, such as
to formability coupled with high strength and good work total elongation, work hardening exponent (n-value), or
hardening ability to stretch and distribute the strain more hole expansion ratio (λ). As an example total elongation (a
[9]. steel property related to formability) is compared to the
Fig. 1 indicates the typical comparison of various tensile strength for the current types of steel, as shown in
materials with respect to their key parameters such as Fig 2 [9].
stiffness, density and cost [9].

Mild: Mild Steel; BH: Bake Hardenable; CP: Complex Phase; DP: Dual
phase; FB: Ferritic Bainitic; HF: Hot Formed and Quenched; HSLA:
High- Strength Low Alloy; IF: Interstitial Free; MS: Martensitic (MART);
TRIP: Transformation Induced Plasticity; TWIP: Twinning Induced
Fig 1 Relative Materials Properties and Costs [15] Plasticity

IV. CLASSIFICATION OF AUTOMOTIVE STEEL Fig 2 Relative Materials Properties and Costs [9]

Automotive steels can be classified in several different The principal difference between conventional HSS
ways. Common designations include low-strength steels and AHSS is their microstructure. Conventional HSS
(interstitial-free and mild steels); conventional HSS are single-phase ferritic steels with a potential for
(carbon-manganese, bake hardenable and high-strength, some pearlite in C-Mn steels. AHSS are primarily steels
low-alloy steels); and the new Advanced High Strength with a microstructure containing a phase other than ferrite,
Steel (AHSS) (dual phase, transformation-induced pearlite, or cementite – for example martensite, bainite,
plasticity, twinning-induced plasticity, ferritic-bainitic, austenite, and/or retained austenite in quantities
complex phase and martensitic steels) [9]. Other types of sufficient to produce unique mechanical properties [9].
steel include hot-formed, post-forming heat-treated steels, Conventional high strength steels are manufactured by
and steels designed for unique applications. adding the alloying elements such as Nb, Ti, V, and/or P in
low carbon or IF (interstitial free) steels [11].

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International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 6, Issue 7, July 2016)
High-strength steels can be little costlier but it provides A. Conventional Low- and High-Strength Automotive
opportunity to use thinner and lighter components. With Sheet Steels
HSS, there can be a tradeoff between strength and Cold-rolled sheet steel with a thickness ranging from 0.5
formability; in other words, the stronger a steel is, e.g., in to 1.5mm is mostly used for body in white. Earlier, soft
resisting stretching (tension), the more difficult it can be to unalloyed materials were preferred because they offer a
forge into shapes, particularly the stylistically and high degree of formability and freedom of design. In
aerodynamically optimized shapes needed for new addition to deep drawing and stretch forming, the
vehicles. Steel suppliers are therefore developing steels suitability for welding, joining, and painting are significant
with a range of properties that give engineers more criteria of processing. These requirements are also met by
flexibility in selecting an ideal grade of steel for any given the higher-strength thin sheets (with a minimum yield point
application [11]. of >180 MPa [12]. At present, there is a tendency toward
Conventional high strength steels (HS) in order of Dual-phase (DP) steels, partially martensitic, and
increasing strength together with advanced high strength transformation induced plasticity (TRIP) steels or
steels (AHS) and high manganese steels (HM) are shown in multiphase (MP) steels [12]. The basic problem with
Table I [11]. AHS steels are multiphase which contain increasing strength is a natural decline in the forming
phases like martensite, bainite, and retained austenite in capability leading to development of new generation steel
sufficient quantities to produce unique mechanical known as Multi-Phase (MP steels) [12]. The raising of the
properties [11].Recently, new group of austenitic steels strength is based on structural hardening. Early HSLA
with high manganese contents has been developed for metallurgy are based on fine ferrite grain size,
automotive use. These are high manganese steels (HMS) precipitation hardening, micro-alloy additions of
which combine and provide excellent combination of columbium, vanadium, titanium and low sulfur and
mechanical properties with an alloying concept less inclusion shape control.
expensive than conventional or new high strength austenitic
1) Mild Steel: Mild steel has having ferritic microstructure
stainless steels. This group is divided into transformation
and provide essentially Drawing Quality (DQ) and
induced plasticity steels (HMS-TRIP) and twinning
Aluminium Killed (AKDQ) steels which are predominantly
induced plasticity steels (HMS-TWIP) due to the
used in automotive application over the years [9].
characteristic phenomena occurring during plastic
deformation [11]. 2) Interstitial-Free (IF) Steels (Low Strength and High
Strength): IF steels have been developed by achieving
Table I ultra-low carbon levels for lower yield strengths and higher
Conventional HS, MS and HMS Steels [11] work hardening exponents (n-values) [9]. These steels have
HS Steels more stretchability than Mild steels. The IF-HS grades
utilize a combination of elements for solid solution
BH Bake hardening strengthening, precipitation of carbides and/or nitrides, and
IFHS High strength IF grain refinement [9]. Phosphorus is added to increase the
P Rephosphorised strength and are widely used for both structural and closure
IS Isotropic applications.
Cmn Carbon/manganese 3) Bake Hardenable (BH) Steels: BH steels have a basic
ferritic microstructure and solid solution strengthening. A
HSLA High Strength Low Alloyed
unique feature of these steels is the chemistry and
AHS steels processing designed to keep carbon in solution during
DP Dual Phase steelmaking and then allowing this carbon to come out of
TRIP Transformation Induced plasticity solution during paint baking or several weeks at room
CP Complex Phase temperature which results in increase in yield strength of
the component for increased dent resistance without
PM Partly Martensite
reduction in formability [9].
HM steels
TRIP high MN transformation induced
HMS plasticity
HMS TWIP high MN twinning induced plasticity

249
International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 6, Issue 7, July 2016)
4) High-Strength Low-Alloy (HSLA) Steels: HSLA steels In comparison to DP steels, CP steels show significantly
increase strength primarily by micro-alloying elements higher yield strengths at equal tensile strengths of 800 MPa
contributing to fine carbide precipitation, substitutional and and greater [9]. CP steels are also characterized by high
interstitial strengthening, and grain-size refinement [9]. energy absorption, high residual deformation capacity and
HSLA steels are used in body-in-white and increased in- good hole expansion. They are used for frame rails, chassis
service load application components. components, transverse beams, B-pillar reinforcements,
5) Micro alloyed Steel: A small amount i.e. 0.01% of tunnel stiffener, Rear suspension brackets, fender beam,
titanium, vanadium, and niobium added for alloy formation rear frame rail reinforcements, rocker outer, rocker panels,
resulting in increase of the yield point to 260–540N/mm2 bumper beams.
and the tensile strength to 350–620 Mpa. Age hardening of 3) TRIP steels: TRIP steels are known as transformation
finely distributed carbon nitrides results in an increase in induced plasticity effect, having high strength, good
the strength and higher-strength drawing properties of the elongation, high energy absorption and high bake
conventional micro alloyed steel [12]. hardening. TRIP steels display high n-value strengthening
6) Isotropic Steel: These steels possess unidirectional flow coefficient up to the limit of uniform elongation. The
characteristics leading to better deep-drawing property and microstructure of TRIP steels is retained austenite
at the same time an increase in their strength. The embedded in a primary matrix of ferrite with some amount
minimum yield point in the delivery status of these sheet of martensite and bainite [9]. TRIP steels use higher
metals ranges between 210 and 280 MPa. These steels too, quantities of carbon than DP steels to obtain sufficient
show a bake-hardening effect after preforming [12]. carbon content for stabilizing the retained austenite phase
to below ambient temperature. Higher contents of silicon
B. AHS Steels and/or aluminium accelerate the ferrite/bainite formation.
Advanced high strength steels are already discussed Silicon and aluminium are used to avoid carbide
earlier which is primarily distinguished based on their precipitation in the bainite region. This steel is used for
microstructural features. They offer extraordinary strength- Frame rails, rail reinforcements, Side rail, crash box, Dash
ductility relationship. panel, roof rails, B-pillar upper, roof rail, engine cradle,
1) Dual phase steels: DP steels consist of a ferritic matrix front and rear rails.
containing a hard martensitic second phase in the form of 4) Martensitic Steels: The MS steels are characterized by
islands. It is produced by controlled cooling from the a martensitic matrix containing small amounts of ferrite
austenite phase (in hot-rolled products) or from the two- and/or Bainite showing high ultimate tensile strength level
phase ferrite plus austenite phase (for continuously up to 1700 MPa. MS steels are produced from the austenite
annealed cold-rolled and hot-dip coated products) to phase by rapid quenching to transform most of the austenite
transform some austenite to ferrite before a rapid cooling to martensite. Using water quenching in a continuous
transforms the remaining austenite to martensite [9],[11]. annealing line, steels with 100 % martensite can be
This steel is used in roof outer, door outer, body side outer, produced [9],[11].
package tray, floor panel, hood outer, body side outer, This structure also can be developed with post forming
cowl, fender, floor reinforcements, Body side inner, quarter heat treatment. MS steels are often subjected to post-
panel inner, rear rails, rear shock Reinforcements, Safety quench tempering to improve ductility, and can provide
cage components (B-pillar, floor panel tunnel, engine adequate formability even at extremely high strengths [11].
cradle, front sub-frame package tray, shotgun, seat), Roof Adding carbon to MS steels increases hardenability and
rails, B-pillar upper etc. strengthens the martensite. Manganese, silicon, chromium,
2) Multiphase (MP) steels or Complex Phase (CP) steels: molybdenum, boron, vanadium, and nickel are also used in
Multiphase steels, also referred to as complex phase steels, various combinations to increase hardenability. They are
provide higher level of yield strength at the same used in Cross-members, side intrusion beams, bumper
comparable tensile strength levels of dual phase steels [9]. beams, bumper reinforcements, rocker outer, side intrusion
The microstructure of CP steels contains small amounts of beams, bumper beams, and bumper reinforcements.
martensite, retained austenite and pearlite within the Ferritic-Bainitic (FB) Steel: FB steels have a
ferrite/bainite matrix. An extreme grain refinement is microstructure of fine ferrite and bainite. Strengthening is
created by retarded recrystallization or precipitation of obtained by both grain refinement and second phase
micro alloying elements like Ti or Nb. hardening with bainite [9].

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International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 6, Issue 7, July 2016)
FB steels sometimes are primarily utilized to meet specific Fig. 3 and 4 depict the current percentage distribution of
customer application requirements that require Stretch various materials for light vehicle in Europe and North
Flangeable (SF) or High Hole Expansion (HHE) America
capabilities for improved edge stretch capability [9]. Table II
Compared to HSLA steels with the same level of strength, North American Light Vehicle Material Content [13]
FB steels also have a higher strain hardening exponent (n-
value) and increased total elongation. They are used in Change
Rim, brake pedal arm, seat cross member, suspension arm, from
Material 1975 2005 2007 2015
FB Lower control arm, rim, bumper beam, chassis parts, 1975 to
and rear twist beam. 2015(lbs)
5) Twinning-Induced Plasticity (TWIP) Steel: TWIP steels Down
Mild Steel 2180 1751 1748 1314
offers extremely high strength (>1000 MPa) with extremely 866
high stretchability. It is developed by adding high HSS 140 324 334 315 Up 175
manganese content (17-24%) which causes the steel to be AHSS - 111 149 403 Up 403
fully austenitic at room temperatures. A large amount of Other Steels 65 76 76 77 Up 12
deformation is driven by the formation of deformation Down
twins. The twinning causes a high value of the Iron 585 290 284 244
341
instantaneous hardening rate (n value) as the microstructure Aluminium 84 307 327 374 Up 290
becomes finer and finer [9]. It is used in A-Pillar, Magnesium - 9 9 22 Up 22
wheelhouse, front side member, wheel, lower control arm,
Other
front and rear bumper beams, B-pillar, wheel rim, floor 120 150 149 145 Up 25
metals
cross-member, wheelhouse, door impact beam.
Plastics/
6) Hot-Formed (HF) Steel: Boron-based hot forming 180 335 340 364 Up 184
Composites
steels (between 0.001% and 0.005% boron) have been in
use since quite long for body-in-white construction. A Other
546 629 634 650 Up 104
typical minimum temperature of 850°C must be maintained Materials
during the forming process (austenitization) followed by a Total
3900 3982 4050 3908 Up 8
cooling rate greater than 50°C/s to ensure that the desired Pounds
mechanical properties are achieved [9]. These steel are
used in A-pillar, B-pillar, cross beam.
7) Manganese–Boron Steels: Manganese–boron steels are
considered for complex geometries with high strength
requirements. For hot forming and hardening, the
manganese–boron steels offer the highest strengths of up to
1650N/mm2 in the hardened condition [12]. High strength
is achieved after heating the steel to the austenitization
temperature followed by controlled cooling results in
martensitic structure.

V. APPLICATION OF AUTOMOTIVE STEEL


Table II shows the trend of usage of various materials in
light vehicle in North America. The trends in the recent
years show decrease in the use of traditional mild steel,
while newer materials like HSS, advanced HSS are beings
used significantly more. With the advancement in
technologies of production newer alloys of aluminium and
magnesium are also being used more. Plastics and
composite with their lightweight and recyclable properties
are also liked by the automotive companies. Fig 3: Light Vehicle Metallic Material Trends , North America [13]

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International Journal of Emerging Technology and Advanced Engineering
Website: www.ijetae.com (ISSN 2250-2459, ISO 9001:2008 Certified Journal, Volume 6, Issue 7, July 2016)

Fig 6: Light Vehicle Metallic Material Trends Europe [14]

Table III indicates typical mechanical properties of


various steel materials and its application in various
components of vehicle [9]
Table III
Mechanical Properties of Various Steel Materials and its Application
Fig 4: Light Vehicle Metallic Material Trends Europe [13] Total n-
YS UTS App.
EL value
The progressive material concept for steel has been Steel grade
(5-
r-bar
represented for future steel vehicle project in Fig 5. MPa MPa (%) Code
15%)
Mild
140 270 38-44 0.23 1.8 A,C,F
140/270
BH 210/340 210 340 34-39 0.18 1.8 B
BH 260/370 260 370 29-34 0.13 1.6 B
IF 260/410 260 410 34-38 0.2 1.7 C
DP 280/600 280 600 30-34 0.21 1 B
IF 300/420 300 420 29-36 0.2 1.6 B
DP300/500 300 500 30-34 0.16 1 B
HSLA
350 450 23-27 0.22 1 A,B,S
350/450
A,B,C,
DP 350/600 350 600 24-30 0.14 1.1
W,S
DP 400/700 400 700 19-25 0.14 1 A,B
TRIP
450 800 26-32 0.24 0.9 A,B
450/800
HSLA
490 600 21-26 0.13 1 W
490/600
A,B,C,
DP 500/800 500 800 14-20 0.14 1
W
SF 570/640 570 640 20-24 0.08 1 S
Fig 5: Light Vehicle Metallic Material Trends Europe [14] CP 700/800 700 800 10-15 0.13 1 B
Future opportunity of next generation advanced high DP 700/1000 700 1000 12-17 0.09 0.9 B
strength steel development has been shown in Fig 6. Mart
950 1200 05-07 0.07 0.9 A,B
950/1200
MnB 1200 1600 04-05 n/a n/a S
Mart
1250 1520 04-06 0.07 0.9 A
1250/1520

Application Code A-ancillary parts, B- Body Structure, C-Closures, F-


Fuel tank, S-suspension/chassis, W-Wheels

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VI. CONCLUSION [4] Ghassemieh, E. 2011 Materials in Automotive Application. State of
the Art and Prospects. New Trends and Developments in
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fulfils the key criteria of material selection viz. stiffness, art-and-prospects
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[9] Keeler, S. and Kimchi, M. 2014 Advanced High Strength Steel
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