·       Safety: the combination of high strength and high formability resists the impact of collisions;

·       Energy efficiency: the steel is hot-formed at lower temperatures;

·       More corrosion protection: thanks to a specific zinc coating that does not crack during hot-forming;

·       Cost savings: due to less tool wear and fewer post‑processing steps. 

Lower energy consumption and improved passenger safety 

Ultra-strong steels used in automotive crash structures are usually hot-formed at very high temperatures. At those temperatures, the zinc coating on the steel can melt, resulting in cracking. For that reason, manufacturers often use aluminium‑silicon coated steels. Those can withstand high temperatures but offer lower corrosion resistance. “By developing this new high‑quality steel grades, we address these limitations,” says Dr. Radhakanta Rana, metallurgist at Tata Steel Nederland and project leader of WarP-AHSS. Dr. Rana explains: “The benefits go beyond energy savings alone. By combining ultra-high strength with exceptional in-service formability, these new steels can absorb significantly more crash energy. This reduces the effect of a collision and increases passenger safety. It is a true breakthrough in steel design and aligns with Tata Steel Nederland’s strategy for more sustainable steel production.” 

Less maintenance and lower production costs 

These new steel grades also offer various benefits for automotive manufacturers. A zinc coating, processed at lower temperatures, eliminates the need for additional processes such as sand‑blasting and provides improved corrosion resistance. This leads to a simpler, more efficient production process, less maintenance, and lower production costs. Dr. Christina Sunderkötter, Project Manager Sustainability Solutions from Volkswagen Group adds: “In addition to reducing environmental impact, we want to offer a steel solution that meets the requirements of future vehicle production: better safety performance, simpler manufacturing processes, and lower part-making costs. Together through WarP‑AHSS, we are working on the next evolution in AHSS technology.” 

WarP-AHSS is funded by the European Research Executive Agency (REA) on behalf of the European Commission. The project runs from 2023 until 2027.

Photo by: David de Jong