A European consortium led by Tata Steel Nederland has made significant progress in developing new zinc-coated ultra-high-strength steels specifically designed for crash structures in automotive manufacturing. In addition to Tata Steel Nederland, the consortium includes the Volkswagen Group, RWTH Aachen University, the National Centre for Metallurgical Research CENIM in Spain, the Swedish Research Institute RISE, and the French Corrosion Institute.
The project is named "Warm Press Formed Zinc Coated Third Generation Advanced High Strength Steels with High Crash and Corrosion Resistance and Minimized Microcracking," or WarP-AHSS for short, and aims to improve passenger safety while supporting more sustainable steel production.
Challenge in Hot Forming of Zinc-Coated Steels
Ultra-high-strength steels used in vehicle impact protection structures are typically hot-formed at very high temperatures. At these temperatures, the zinc coating on the steel can melt, leading to crack formation. For this reason, manufacturers frequently use steels with aluminium-silicon coatings. These can withstand high temperatures but offer lower corrosion resistance.
"By developing this new highquality 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."
Benefits for Automotive Manufacturers
The new steel grades also offer various advantages for automotive manufacturers. A zinc coating processed at lower temperatures eliminates additional steps such as sandblasting and provides improved corrosion resistance. This results in a simpler, more efficient production process, less maintenance, and lower production costs.
Dr. Christina Sunderkötter, Project Manager Sustainability Solutions at the 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 WarPAHSS, we are working on the next evolution in AHSS technology."
EU-Funded Research Project Running Until 2027
WarP-AHSS is funded by the European Research Executive Agency (REA) on behalf of the European Commission. The project runs from 2023 to 2027.
