Steel Mills

Steel Makes a Comeback in Audi A8
Written by Sandy Williams
May 14, 2017
The following article was provided and first published by ArcelorMittal USA news:
After experimenting with aluminum in its luxury models, Audi’s next A8 will switch back to steel. Scheduled for release in 2018, the body structure of the new A8 will be made up of more than 40 percent steel, following the trend of automakers opting to use advanced high-strength steels in new vehicles. That’s a marked turnaround from the all-aluminum body-in-white which Audi developed for the A8 in 1994.
Since, steel has evolved dramatically. In fact, steel’s strength has multiplied by almost 10 times over the past 20 years, from 270 to 2000MPa tensile strength. More than 80 new steel products are under development at ArcelorMittal, with an automotive steel grade portfolio of almost 200 unique steel grades, half of which were introduced in just the past decade.
Around 17 percent of the new A8 body structure will be comprised of press hardenable steel (PHS), some of which will be supplied by ArcelorMittal. These steels have yield strengths up to 1500 MPa after press hardening. The strength-to-weight ratio of these grades outperforms even the most advanced – and costlier – aluminum grades. With the advent of new joining technologies, it has never been easier for automakers to incorporate advanced high-strength steels into their vehicles. As these technologies mature and are adopted by carmakers, the use of PHS in the multi-material vehicles of the future is set to grow rapidly.
“Usibor® is our key product in hot stamping and has been a major commercial and technical success in the global automotive industry,” said Brian Aranha, executive vice president, global automotive, ArcelorMittal. “Looking ahead, the scope of hot stamping products in vehicles will continue to increase with the release of more advanced products like Usibor® 2000, which offers 10 to 15 percent weight savings when compared to existing hot stamping solutions.”
Usibor® is compatible with standard press hardening technologies and processes. Combining Usibor® with Ductibor® into laser welded blanks offers several significant advantages including weight savings, improved crash behavior and cost savings through material and manufacturing optimization.
Dr. Bernd Mlekusch, head of the Audi’s Leichtbauzentrum, or Lightweight Construction Center, said: “There will be no cars made of aluminum alone in the future. Press hardened steels (PHS) will play a special role in this development. PHS grades are at the core of a car’s occupant cell, which protects the driver and passengers in case of a collision. If you compare the stiffness-weight ratio, PHS is currently ahead of aluminum.”
Audi’s switch back to steel is part of a growing trend which is even surpassing the expectations of steelmakers, according to data released by the Steel Market Development Institute (SMDI).
Between 2006 and 2015, the use of advanced high-strength steels in vehicles has grown from an average of 81 pounds per vehicle (36.7 kg) to 275 pounds (124 kg). That’s a threefold increase in just 10 years. What’s more surprising is that over the period 2012 to 2015, the use of AHSS has increased by around 10 percent each year, well above steel industry forecasts.
ArcelorMittal and the steel industry as a whole have been working collaboratively to educate automakers and stakeholders on the importance of life cycle analysis, or LCA. LCA looks at total emissions generated during the three stages of a vehicle’s life – production, drive phase and disposal.
“Right now, regulations only consider tailpipe emissions generated during the drive phase,” said Brad Davey, chief marketing officer, NAFTA and global automotive for ArcelorMittal. “However, each material used in vehicle production contributes to lightweighting and improves fuel economy, but each does so at a different cost to the manufacturer – and to the environment.”
Studies show that aluminum produced in North America emits four to five times more GHGs than steel. Additionally, aluminum requires seven times more energy to produce than steel.
“If we want to know how “green” a vehicle really is, we have to measure emissions over its entire life cycle. Otherwise, choosing an alternative material over advanced steel will result in a huge and irreversible environmental mistake,” said Davey.

Sandy Williams
Read more from Sandy WilliamsLatest in Steel Mills

Atlas completes Evraz NA deal, renames firm, and hires former USS exec as CEO
Atlas Holdings has completed its acquisition of Evraz North America (Evraz NA) and its subsidiaries.

ArcelorMittal: As tariffs slow global growth, Calvert could be a bright spot
ArcelorMittal expects less demand growth across most of the markets it operates in, including the US, because of President Donald Trump’s tariffs. But the Luxembourg-based steelmaker also thinks it stands to benefit from an increasingly regionalized world thanks to investments like the new EAF at its mill in Calvert, Ala.

Ternium posts solid Q2, expects further shipment growth
Latin American steel producer Ternium delivered a solid performance in the second quarter of 2025. Performance was driven primarily by higher realized steel prices in Mexico, even as shipment volumes declined slightly across its regional portfolio.

Algoma swings to loss on ‘unprecedented disruptions’ and trade barriers
Canada’s Algoma Steel saw a sharp loss in the second quarter amid a continued challenging market environment and “tariff uncertainties.”

Nucor eyes long-term gains amid strong demand and trade enforcement
Resilient demand across its steel product lines, combined with the continued ramp-up of key expansion projects, drove Nucor’s improved financial results and record-setting performance in the second quarter. That’s according to company executives speaking on an earnings conference call on Tuesday.