Automotive

Due to diverse grades and advanced production techniques stainless steel has progressed well beyond the exceptional corrosion resistance it brings to car exhaust systems. Stainless steel is now an excellent choice for a variety of automotive applications – from car bodies to structural components and from power train solutions to intricate design elements.

Body-in-white (BIW) and structural components

The body-in-white (BIW) is the stage during vehicle manufacturing where all the individual components of the vehicle body are joined together. Stainless steel provides excellent strength and stiffness to the BIW and its high impact resistance greatly increases the safety of the driver and passengers. Other structural components include items such as cross members, crash boxes, door-side impact beams, pillars and further reinforcing elements. The high ductility, formability and weldability of stainless steel allow for endless possibilities.

Internal combustion engines and GDI systems

Stainless steel is being increasingly used in internal combustion engines due to its strength, toughness, corrosion resistance and excellent high temperature properties. Applications include exhaust valves, head gaskets and pump bodies.

Stainless steel can also greatly improve the fuel efficiency, increase torque and horsepower, and reduce emissions of Gasoline Direct Injection (GDI) components such as high-pressure fuel pumps, fuel rail fittings, connectors and spray nozzles.

Electric vehicle (EV) traction motors and battery compartments

Electric traction motors, used in both hybrid and fully-electric vehicles, benefit greatly from fully austenitic stainless steel. It is completely non-magnetic so is ideally suited for electric motor components such as shafts, support discs and shrouds. It also offers excellent heat resistant to temperatures up to 300°C.

A significant challenge for EV manufacturers is the design of safe, light and cost-effective battery compartments to house the large lithium-ion battery packs that provide traction power. In addition to saving weight and high crash resistance, the key factor is heat resistance in case of fire. Unlike typically used aluminum, austenitic stainless steel grades can survive temperatures up to 1300°C for over 10 minutes with only a small deflection offering more time for emergency personnel.

PEM fuel cells

Hydrogen-accelerated vehicles benefit from stainless steel’s ideal combination of electrical conductivity, high corrosion resistance, and strength needed to manufacture bipolar plates. Additionally, it offers excellent formability and lower costs compared to graphite.

Exhaust systems

The exceptional corrosion resistance of stainless steel has made it a staple in vehicle exhaust systems, especially around the catalytic converter area, and in components including manifold, downpipe, catalytic converter, resonator, intermediate pipe, and silencer.

Fuel tanks

In automotive fuel tanks, the material of choice is generally plastic. However, stainless steel enables a lighter, safer and more durable alternative that offers high resistance against internal pressure. It is also compatible with complex forming operations and is fully recyclable.

Internal components

Internal components such as seat structures and steering columns require stiff materials that resist fatigue, offer high impact adsorption for crash safety and are also suitable for complex forming processes. Stainless steel offers the ideal combination of these properties and does not require painting.

Exterior surface layer

With stainless steel the exterior surface of vehicles can be made without the need for additional coatings or treatments. In addition to being inherently corrosion-resistant, stainless steel offers a stylistic choice.

Trim elements, small parts and accessories

Stainless steel offers high durability, elegant design, aesthetically pleasing appearance and ease of forming into complex shapes for interior and exterior decorative trim such as door handles and trim strips. Additionally, it is an easily cleanable and hygienic material for touch surfaces.

The corrosion resistance, toughness and ease of fabrication of stainless steel is employed in a wide variety of small machined parts and accessories, including hose clamps, springs, windshield wipers and safety straps.