The International Molybdenum Association (IMOA), London, has published a study demonstrating that lightweight components manufactured from advanced high-strength steel (AHSS) can reduce attributable greenhouse gas emissions by around 29% compared with traditional component designs. The study, conducted by PE International, measures the lifetime environmental impact of replacing the B-Pillar in the latest Ford Fusion model with a new AHSS design.
The B-Pillar is one of the most critical components in a vehicle body, protecting occupants by helping to maintain structural integrity in a side impact. Traditionally made from press-hardened boron steel, it has been replaced in the new model with a hydro-formed component made from a mix of DP800 and DP1000 steels. The molybdenum in the steel supports modern forming processes while imparting exceptional strength, reducing the amount of steel required and making the new B-Pillar just as strong but 4 kg lighter.
The environmental benefit was calculated using life cycle assessment (LCA) to measure the total lifetime environmental impact from manufacture and use through to end-of-life. A number of environmental metrics relevant to vehicle performance were used, covering climate change, air pollution and energy resource use.
The results generated indicate that the new design has a lower impact across all environmental metrics assessed, with a saving of 29% in Global Warming Potential (GWP) compared with the previous component. Over an estimated lifetime mileage of 200,000 km, this equates to a GWP saving for both B-Pillars of 165 kg CO2e for a petrol drivetrain, and 141 kg CO2e for a diesel drivetrain. This is a saving equivalent to the emissions from driving the vehicle for over 1000 km. The new B-Pillar also performs better in side impact crash tests, and Ford estimates that it has yielded a significant cost saving.
