Electrification in the automotive sector

The only thing we really know about the future of the automotive sector is that change will continue and to an extent that we can hardly imagine. For a passenger car, converted from a drivetrain based on an internal combustion engine to fully electric, the use of engineering steel will be reduced by up to about 50%. The total market share of electrified vehicles (EVs) will also be larger for light vehicles than for heavy vehicles. For Ovako, this is a challenge we have been preparing for since we founded our Industry Solutions Development (ISD) function, seven years ago. Our ISD is responsible for handling end-user system demands.

With our internal team of experts in engine and transmission design, working in close cooperation with Group R&D, we have tried to address the step changes in the automotive industry. One key measure is to provide steels with the world’s measurably lowest carbon dioxide footprint from cradle to gate. At the same time, we offer high performing steel solutions for both powertrain and chassis systems. Our range of solutions and technical support have aim to improve Ovako’s position as a trusted advisor and supplier to the automotive industry.

Modern steel performance in calculation software

To evaluate and implement high performance steels in the creation of new design possibilities has never been easy. Finding the right tools to combine the increased performance of modern steels with classical mechanical design has been a particular challenge. This is because current standards, such as ISO 6336-5, have been tied to the specific performance levels of conventional steels. However, the Ovako BQ- and IQ-Steel families show a significantly increased fatigue endurance performance for what is generally classified as the same grade of steel. Implementation of this increased material performance in gear design has been a missing link.

It provides possibilities to achieve new targets for power density that have not been possible before. The increased material performance can also be used to find new solutions for other aspects of the design, such as efficiency and NVH (noise, vibration and harshness) behavior. We are continuing our cooperation with GWJ and further machine elements are on the way. Stay in touch and we will make sure you get the latest updates.

A powerful Ovako E-drive concept

Ovako recently participated in the Swedish government supported Strategic Innovation Program called LIGHTer. The aim was to develop an E-drive transmission concept to showcase the design possibilities resulting from increased material performance. The concept uses high performance IQ-steel in combination with the mechanical Belix technology that balances the gear forces internally in the system. The solution was dimensioned according to load data collected from an A-Class sized vehicle and was simulated and analyzed with the GWJ software. The transmission features helical gears in a layshaft design and is considered less complex than planetary solutions.

The simplicity of the concept in combination with its high performance enhances its possibilities for industrialization. The concept aim to be the basis for continued development of electric powertrains whileallowing for easy scaling in terms of vehicle integration and power output. Compared to current solutions on the market we estimate a potential weight reduction of about 30%. Other properties such as efficiency and NVH are also improved thanks to the changes in the gear design made possible by the increased steel performance of the Ovako IQ-Steel family. The collaborative project was carried out with software from GWJ Technology, manufacturing solutions by Leax Group, and a differential solution from Winning BLW. We are preparing a technical report about the concept, and if you would like a copy, do not hesitate to contact us. And if you want support with your own concept developments and steels for prototyping, click on the link for further information.

Join our upcoming digital events

Thank you to all who joined our first of three Hybrid Steel webinars on March 22. We believe it was a good success and we counted some 115 participants and many interesting questions that we have done our best to respond to. This gave us encouragement for more of the same and we now have a schedule for the coming months. The series on Hybrid Steel will be continued in a second seminar on May 25, where we will explore its mechanical strength properties at elevated temperatures. We also have a digital event on sustainability scheduled for June 9, where we will present details of our position as a leader in carbon neutral steel. Links for booking your participation below.

First out however is the H2 Forum 2021 [Digital Edition] on April 27 and 28, 2021. There are already 2,270+ attendees from 70+ countries registered. During this conference Ovako’s Göran Nyström will participate in the “Masterclass: Making industrial Europe CO2-neutral” on April 28, at 13.00 CET and present its concept for using hydrogen and oxygen from electrolysis for heating steel. We have received a special invitation that you can use to join the meeting at no cost, see below link.