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A perfect fit: Tailored portfolio for cost-effective lightweight steel seat structures

Tailored portfolio with best forming properties for cost-effective lightweight steel seat structures

Front and rear seats must meet the highest demands in terms of economy, installation space, lightweight design, safety, and comfort.

thyssenkrupp Steel offers a tailored portfolio with best forming properties for cost-effective lightweight steel seat structures: From highly ductile hot-rolled strip and medium-wide strip to micro-alloyed cold-forming steels and cold-rolled high-strength multiphase steels – with best forming and joining properties.

New: For ideal material selection thyssenkrupp Steel provides material cards for hot-rolled steels.

Modern car seat has to be a true all-rounder: it has to be lightweight yet crash-proof, take up very little installation space, be inexpensive to produce – and all of this, of course, without compromising comfort. The use of high-strength steel helps to meet these diverse requirements.

Take the issue of weight, for example: Today, each seat weighs on average around 12.5 kilograms – and that’s just the load-bearing steel seat structures. Together, then, the front and rear seat structures of a car can easily weigh in at around 50 kilos. A tailored portfolio of steel grades to meet to the specific seating requirements have a noticeable positive impact here and help reduce weight by up to 15 percent – at no extra cost.

Overview front seat structure

Maßgeschneidertes Portfolio mit besten Umformeigenschaften für wirtschaftliche Leichtbau-Sitzstrukturen.
Seat rails, standard thickness 1.5 to 2.0 mm

precidur® HSM 700 HD

perform® 550 HD

CP-K® 780Y980T2

Transverse tubes, standard thickness 2.0 to 2.5 mm

perform® 355

DP-K® 440Y780T HHE

CP-K® 570Y780T

Seat shell, standard thickness 0.8 mm

MHZ® 340

MHZ® 380

DP-K® 290Y490T

Cushion side member, standard thickness 1.6 mm

perform® 500 HD

CP-W® 660Y760T

DP-K® 700Y980T

Upper seatback crossbar, standard thickness 0.8 to 1.1 mm

MHZ® 420

Lower seatback crossbar, standard thickness 0.8 to 1.0 mm

DP-K® 440Y780T HHE

MHZ® 420

Backrest side member, standard thickness 0.8 to 1.1 mm

DP-K® 440Y780T HHE

DP-K® 590Y980T

DP-K® 700Y980T

Adapter unit, standard thickness 3.0 to 5.0 mm

precidur® HLB 22

precidur® HSM 700 HD

precidur® HSM 650 HD

scalur® S600MC

Seat height adjuster, standard thickness 3.0 to 5.0 mm

precidur® HLB 37

Articulated lever, standard thickness 3.0 to 5.0 mm

precidur® HSM 700 HD

Backrest side member

Seat structures are a complex system in which every single structural component is important. Take safety: The front seatback is stressed by the passenger in the event of a rear-end crash and by whatever’s on the rear seat or possibly in the trunk in a frontal collision. Accordingly, different crash load cases must be considered for the backrest side member, cushion side member, and seat shell.

A task made for our robust high strength dual-phase steel DP-K® 440Y780T HHE. With a rating of 800 MPa, this cold-rolled dual-phase steel is not only extremely strong but also easy to form, making it perfect for difficult-to-form structural components that are exposed in the event of a crash, such as the backrest side member.


Material recommendation:

  • DP-K® 440Y780T HHE
    DP-K® 590Y980T
    DP-K® 700Y980T
    Benefit: High strength with good formability for maximum weight savings

Cushion side member

Depending on the shape of the component in question, dual-phase steel DP-K® 700Y980T or highly ductile micro-alloyed steel perform® 500 HD can be used, e.g., for the cushion side member (the new HD steel grade is particularly easy to form).

Material recommendation:

  • perform® 500 HD
    Benefit: High strength and good formability
  • CP-W® 660Y760T
    Benefit: High yield and tensile strength as well as good bending and edge formability
  • DP-K® 700Y980T
    Benefit: High strength with good formability for maximum weight savings

Seat rails

Highly ductile micro-alloyed, high-strength perform® steels (hot wide strip) as well as precidur® steel grades made from Hohenlimburg precision steel in particular are ideal for classic cold-rolling processes and seat rail applications. Finally, the cold-rolled uncoated complex-phase steel CP-K® 780Y980T is another high-performance material in the 1,000 MPa strength class that features excellent forming properties and meets the highest thickness tolerance requirements – and not only for seat rails.

Material recommendation:

  • perform® 550 HD
    Benefit: High strength and good formability
  • precidur® HSM 700 HD
    Benefit: Especially suited to complex forming processes
  • CP-K® 780Y980T2
    Benfit: High lightweight potential

Adapter unit, seat height adjuster and articulated lever

The case-hardening and tempered steels and the highly ductile micro-alloyed fine-grain structural steels of the precidur® family, for example, offer hot-rolled precision strip with extremely tight thickness and profile tolerances that is ideally suited to making functional components such as adapter units, seat height adjusters and articulated levers.

Material recommendation adapter unit:

  • precidur® HLB 22
    Benefit: Good processing and forming properties in hot-rolled and annealed condition
  • precidur® HSM 650 HD
    precidur® HSM 700 HD
    Benefit: Especially suited to complex forming processes
  • scalur® S600MC
    Benefit: High lightweight potential and best processing properties

Material recommendation seat height adjuster:

  • precidur® HLB 37
    Benefit: Good processing and forming properties in hot rolled and annealed condition

Material recommendation articulated lever:

  • precidur® HSM 650 HD
    precidur® HSM 700 HD
    Benfit: Especially suited to complex forming processes

Overview rear seat structure

Maßgeschneidertes Portfolio mit besten Umformeigenschaften für wirtschaftliche Leichtbau-Rücksitzbänke
Rear seat panel, standard thickness 0.5 to 0.6 mm

DP-K® 290Y490T (tolerances ±0.05 mm, tighter tolerances on request)

MHZ® 420, standard thickness approx. 0.6 mm

HC460LA, standard thickness approx. 0.5 mm

Reinforcement brackets, standard thickness 2.0 to 2.5 mm

scalur® S420MC

Profiles, standard thickness 0.8 to 1.2 mm

DP-K® 700Y980T, ideal for roll forming

CP-K® 570Y780T

DP-K® 440Y780T

HC460LA

Rear seat panels and reinforcement brackets

While seat structures for front seats have the same or comparable structure depending on the car model, rear seat structures vary greatly depending on the vehicle, e.g. adjustable individual seats, divisible or non-divisible rear seat benches with profiles or tubes.

Micro-alloyed steels MHZ® 420 and HC460LA are predestined for forming operations such as flanging and beading and therefore ideally suited for the production of rear seat panels. Profiles and reinforcement brackets are used to meet the high crash requirements of the rear bench seat (e.g. load case: protection against load). Our steel grade scalur® S420MC, pickled micro-alloyed hot-rolled strip with extremely narrow thickness tolerances of up to ±0.05 mm and a very flat profile, offers not only the best processing properties but also high lightweighting potential.

Material recommendation rear seat panels:

  • DP-K® 290Y490T (optional: suitable for laser hardening)
    Benefit: Innovative lightweight solution
  • MHZ® 420, usual thickness approx. 0.6 mm
    HC460LA, usual thickness approx. 0.5 mm
    Benefit: Excellent forming properties for operations such as flanging and beading

Material recommendation reinforcement brackets:

  • scalur® S420MC
    Benefits:
    - High lightweight potential and best processing properties
    - Excellent suitability for MIG, MAG and laser welding

Profiles

Dual-phase steel DP-K® 700Y980T (ideally suited for roll forming) and complex-phase steel CP-K® 570Y780T are both suitable for rear seat structures in tubular design. Both steel grades combine high strength with good formability and offer high lightweighting potential.

Material recommendation:

  • DP-K® 700Y980T
    CP-K® 570Y780T
    HC460LA
    Benefits:
    - High strength with good formability and high lightweight potential
    - Ideal for structural components with high crash performance (load scenario: protection against cargo)

Highly ductile micro-alloyed steel grades for better forming performance in automotive engineering

Highly ductile micro-alloyed steels are the go-to material when significantly improved formability for complex component geometries in seat structures, like cushion side members and seat rails, is required. They offer better formability and higher hole expansion values. The special microstructure of the HD grades ensures stable mechanical properties (low scatter), the best prerequisite for high production reliability.

Highly ductile micro-alloyed steels for the automotive industry are available as hot wide strip and as precision strip precidur® HSM HD with particularly narrow tolerances.

Overview products seat structures

Dual-phase steel, uncoated (UC)

Steel grade
­
­
Reference grade
DIN EN 10152
Reference grade
VDA 239-100
DP-K® 290Y490T
HCT490X CR290Y490T-DP
DP-K® 330Y590T
HCT590X CR330Y590T-DP
DP-K® 440Y780T HHE1
DP-K® 590Y980T2 HCT980X CR590Y980T-DP
DP-K® 700Y980T HCT980XG CR700Y980T-DP
1. Steel grade with improved hole expansion | 2. Under development

Complex-phase steel, uncoated (UC)

Steel grade
­
­
Reference grade
DIN EN 10152
Reference grade
VDA 239-100
CP-W® 660Y760T HDT760C HR660Y760T-CP
CP-K® 570Y780T HCT780C CR570Y780T-CP
CP-K® 780Y980T2 HCT980C CR780Y980T-CP
2. Under development

Micro-alloyed fine-grain structural steel (Hot-rolled strip, hot-dip galvanized)

Steel grade
­
­
Reference grade
DIN EN 10346

­
Reference grade
VDA 239-100

­
Thickness1
from _ to in mm
­
Width1
from _ to in mm
­
MHZ® 340 HX340LAD HR340LA 1.50 – 4.00 900 – 1,550
MHZ® 380 HX380LAD HR380LA 1.50 – 4.00 900 – 1,550
MHZ® 420 HX420LAD HR420LA 1.50 – 4.00 900 – 1,550
MHZ® 460 HX460LAD HR460LA 1.80 – 3.00 900 – 1,500
1. Not all thickness and width combinations possible.

Highly ductile micro-alloyed steel for cold forming (Hot-rolled strip, uncoated)
VDA 239-100, DIN EN 10149-2

Steel grade
­
­
Reference grade
DIN EN 10149-2
Reference grade
VDA 239-100
Material no.
­
­
Thickness1
from _ to in mm
Width1
from _ to in mm
perform® 315 HD S315MC 1.0972 1.50 – 6.00 50 – 1,600
perform® 340 HD S340MC HR340LA 1.50 – 6.00 50 – 1,600
perform® 355 HD S355MC 1.0976 1.50 – 6.00 50 – 1,600
perform® 420 HD S420MC HR420LA 1.0980 2.00 – 5.00 50 – 1,600
perform® 460 HD S460MC HR460LA 1.0982 2.00 – 5.00 50 – 1,600
perform® 500 HD2 S500MC HR500LA 1.0984 2.00 – 5.00 50 – 1.600
perform® 550 HD S550MC HR550LA 1.0986 2.00 – 5.00 50 – 1,600
1. Not all thickness and width combinations possible. | 2. Available in the product version scalur®.

Micro-alloyed steel for cold forming (Hot-rolled strip, uncoated)
VDA 239-100, DIN EN 10149-2

Steel grade
­
­
Reference grade
DIN EN 10149-2
Reference grade
VDA 239-100
Material no.
­
­
THICKNESS1
from _ to in mm
WIDTH1
from _ to in mm
perform® 300 HR300LA 1.50 – 20.00 50 – 2,030
perform® 3152 S315MC 1.0972 1.50 – 20.00 50 – 2,030
perform® 340 HR340LA 1.50 – 20.00 50 – 2,030
perform® 3552 S355MC 1.0976 1.50 – 20.00 50 – 2,030
perform® 3802 HR380LA 1.0978 1.50 – 20.00 50 – 2,030
perform® 4202 S420MC HR420LA 1.0980 1.75 – 20.00 50 – 2,030
perform® 4602 S460MC HR460LA 1.0982 1.75 – 20.00 50 – 2,030
perform® 5002 S500MC HR500LA 1.0984 1.75 – 16.00 50 – 2,030
perform® 5502 S550MC HR550LA 1.0986 2.00 – 8.50 60 – 1,850
perform® 6002 S600MC 1.8969 3.00 – 9.50 80 – 1,750
perform® 6502 S650MC 1.8976 3.00 – 10.50 80 – 1,750
perform® 7002 S700MC HR700LA 1.8974 3.00 – 12.00 80 – 1,750
1. Not all thickness and width combinations possible. | 2. Available in the product version scalur®.

Micro-alloyed fine-grain structural steel HD grades (Precision strip)

Steel grade
­
­
Standard designation
DIN EN 10149-2
Standard designation
VDA 239-100

­
Material no.
­
­
Thickness1
from _ to in mm
­
Width1
max. in mm
­
precidur® HSM 650 HD S650MC - 1.8976 1.50 – 16.00 720
precidur® HSM 700 HD S700MC HR700LA 1.8974 1.50 – 16.00 720
1. Not all thickness and width combinations possible.

Boron-alloyed heat-treatable steel (Manganese-boron steel)

Steel grade
­
­
Standard designation
DIN EN 10083
Material no.
­
­
Thickness1
from _ to in mm
­
Width1
max. in mm
­
precidur® HLB 22 22MnB5 1.5528 1.50 – 16.00 720
precidur® HLB 37 37MnB4 1.5524 1.50 – 16.00 720
1. Not all thickness and width combinations possible.

Service: All on one material card

Material cards for selected hot-rolled micro-alloyed steels

Every second new car is equipped with at least one Brose vehicle component. The portfolio also includes seat components and structures for which the successful family-owned company sources hot-rolled micro-alloyed steels from thyssenkrupp Steel. In a joint development project and with the support of thyssenkrupp Materials Processing Europe's supply chain expertise, the partners have examined various grades of our micro-alloyed scalur® steels and documented the results on material cards.

Hot-rolled micro-alloyed steels for the automotive industry

The pickled hot-rolled strip scalur® is characterized by very tight tolerances of up to ± 0.05 mm with a very flat profile. Users can thus order thinner strip and thus reduce the component weight, especially when using higher-strength steel grades. At the same time, the steel possesses excellent forming properties and a quality comparable to that of cold strip.

scalur® enables us to use hot strip where cold strip used to be the go-to material,without compromising comfort or safety. Another decisive factor for our choice was that the material meets our specific material requirements.

Gerald Erdmann, Brose, Materials Technology

Simulting an emergency

How does the material behave in the event of a collision? And how in a forming operation? The reliable characterization of the material properties before it is used is of key importance for Brose. A set of material constants has been developed in cooperation with the application technology department of thyssenkrupp Steel and the Mannheim site of the Group’s own Service Centers of thyssenkrupp Materials Processing Europe.

Enrico Thiele, Brose Key Account Manager at thyssenkrupp Materials Processing Europe and Achim Peuster, Technical Customer Account Manager at thyssenkrupp Steel have worked together and in close coordination with the customer to ensure that the specific requirements of the automotive supplier are met. The basis for this cooperation were various experimental analyses to determine the characteristic values and subsequent simulations for validation purposes. In real-life tests, among other things, high-tech testing machines were used that deliver reliable results even for high strengths. In the next step, the experts selected the appropriate mathematical models to simulate the material properties in various programs. So far, thyssenkrupp Steel mainly prepared material constants of hot strip steels as standard dataset for simple simulations.

Together with Brose, we have now for the first time developed complex material cards of selected scalur® grades from S315MC to S700MC for numerical simulation.

Achim Peuster, thyssenkrupp Steel, Technical Customer Service

The material cards contain, for example, the mechanical-technological characteristic values from tensile and fracture tests as well as extensive plasticity and failure descriptions. The advantage for Brose is that the seat manufacturer can use the higher-quality complex data at an early stage of development to determine whether the geometry of a component will meet the load requirements.

Conserving valuable resources

The joint development work took six months. Both parties are satisfied with the result. After all, every virtual simulation in the run-up to production not only saves valuable resources, but also a lot of time.

The material cards represent the properties of scalur® and allow us to take them into account in the simulation of forming processes and load cases before production starts.

Dominik Biniszewski, Brose, Project engineer for simulation

This and the secure supply of materials via thyssenkrupp Materials Processing Europe's Service Centers is an important advantage for the just-in-time processes of the automotive industry.

General inquiry

*

*Mandatory

Contact

thyssenkrupp Steel Europe AG

Kaiser-Wilhelm-Strasse 100

47166 Duisburg, Germany

+49 (0)203 52-0

Overview product portfolio for the automotive industry: uncoated hot strip, precision steel strip and coated steels

Uncoated hot strip

Hot strip - impressive variety within the range of steel grades and dimensions

Product details

Precision steel strip

precidur® – the highest-grade hot-rolled precision strip

Product details

Coated products

Coated products – comprehensive portfolio of hot-dip finished sheet steels and electrolytically galvanized sheet steel

Product details
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