February 2024 Volume 6

MATERIALS

Overcoming Lightweighting Challenges: The Clean Steel Advantage By Troy Kaczorowski

In the pursuit of reducing weight and cost while simultaneously advancing sustainability, manufacturers are constantly looking for ways to enhance their approach without sacrificing the quality of their products. One prominent strategy employed across various manufacturing sectors to achieve these goals is lightweighting. While frequently associated with the automotive industry, the practice of lightweighting is embraced by various industries where product weight significantly impacts functionality. For original equipment manufacturers (OEMs) in the automotive and aerospace industries, lightweighting holds the key to improving fuel efficiency—a critical factor in enhancing the range of modern electric vehicles (EVs). Similarly, the construction sector benefits from the use of lightweight components, streamlining building processes. Regardless of the manufacturing facet, the reduction of weight or number of steel components translates to substantial cost savings, as less material is required to achieve equivalent strength levels. While OEMs prioritize components that balance reliability and performance with a commitment to sustainability, the role of

clean steel cannot be overstated. Collaborating with suppliers that are dedicated to the development of cleaner, higher-strength steel variants enables OEMs not only to deliver high-performance products but also to contribute to a greener and more sustainable future. The Role of Clean Steel in Lightweighting Advancements in steel manufacturing have significantly enhanced steel quality, leading to the emergence of “clean steel.” This term is defined as steel that is free of detrimental nonmetallic inclusions, which are typically introduced during the steelmaking process through standard deoxidation, atmospheric reoxidation, refractory erosion and slag entrainment. If left unaddressed, inclusions exceeding a specific size and chemical threshold can lead to critical defects in steel components, potentially resulting in product recalls. Because recalls stemming from nonmetallic inclusion defects tend to be very expensive, risk mitigation for parts susceptible to nonmetallic inclusion induced failures results in over-engineering parts in terms of size, weight and cost.

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