6 11, 2024

Metal Processing for Electric Vehicles: When Steel and Aluminum are Needed

jane2024-11-06T15:00:59+00:00November 6th, 2024|News Blog, NMC Media|

As the electric vehicle (EV) market expands, strategic use of materials like steel and aluminum has become critical in achieving performance, sustainability, and cost objectives. Metal processing for electric vehicles is a complex field where the selection of materials can significantly influence vehicle design and manufacturing efficiency. Both automotive aluminum and automotive steel play pivotal roles, each offering distinct advantages that can enhance or hinder a vehicle’s performance, range, and cost-effectiveness.

The Steel vs. Aluminum Debate in Metal Processing for Electric Vehicles

In the electric vehicle (EV) industry, a competition between steel and aluminum has emerged, with manufacturers weighing the pros and cons of each material for specific applications. Steel, including ultra-high-strength (UHHS) and advanced high-strength steel (AHHS), is valued for its strength and cost-effectiveness. Aluminum, on the other hand, is favored for its lightweight properties and thermal conductivity, making it ideal for battery enclosures and body panels.

As original equipment manufacturers (OEMs) and EV automakers strive to optimize their vehicles, choosing steel and aluminum becomes a strategic decision. This decision is influenced not only by the materials’ inherent properties but also by factors like supply chain management, the capabilities of steel service centers and metal processing centers, and the demands of EV infrastructure. Understanding the benefits and limitations of each material can guide manufacturers in creating electric vehicles that meet the highest performance and sustainability standards.

The Case for Steel

Advantages of Automotive Steel in Electric Vehicle Manufacturing

Automotive steel, particularly ultra-high-strength steel (UHHS) and advanced high-strength steel (AHHS), offers exceptional strength and durability, making it ideal for structural components that must withstand significant stress, such as the vehicle frame and chassis. In addition to its robustness, steel is generally more cost-effective than aluminum, making it a preferred choice for manufacturers with budget constraints. This is especially important for original equipment manufacturers (OEMs) looking to optimize production costs.

Furthermore, steel is highly recyclable, aligning with sustainability goals and reducing the carbon footprint of vehicle production. The use of galvanized steel also enhances longevity and corrosion resistance in automotive components.

Challenges of Using Steel in Electric Vehicles

One downside of using steel is its weight, as it is significantly heavier than aluminum. This added weight can negatively affect a vehicle’s overall efficiency and range, making it less ideal for electric vehicles focused on maximizing energy efficiency. Additionally, although advancements in galvanization have improved steel’s resistance to rust, it remains more susceptible to corrosion than aluminum, particularly in harsh environmental conditions.

The Case for Aluminum

Benefits of Aluminum in Electric Vehicles

Aluminum’s lightweight nature makes it an ideal choice for reducing vehicle weight, improving fuel efficiency, and extending the range of electric vehicles. For EV automakers, automotive […]

8 04, 2024

Galvanized Steel for Solar Tracking: Applications and Capabilities

jane2024-04-10T15:16:06+00:00April 8th, 2024|News Blog|

The immense potential of solar power as a renewable energy source is globally acknowledged, leveraging the abundant, clean, and accessible energy from the sun. To maximize sunlight capture throughout the day, solar panels need to be optimally oriented, a task achieved by solar trackers. Furthermore, these devices adjust solar panels or collectors to follow the sun’s path. Significantly, this enhances their efficiency and energy output by 25% to 40% over fixed installations.

What makes a well-designed solar tracker? What material can support the weight and movement of solar panels or collectors while resisting corrosion and rust from exposure to the elements? It’s simple. The answer is galvanized steel.

This blog will explore the role and benefits of galvanized steel for solar tracking and how it can help you achieve your green energy goals. Stay tuned and learn more about galvanized steel for solar tracking and how the leading steel service center, National Material Company, can enhance your sustainable energy projects.

Galvanized steel is an incredibly powerful material that should not be underestimated.

To produce galvanized steel, manufacturers apply a layer of zinc to the steel, which prevents rust and corrosion. In fact, the function of the zinc coating is to act as a sacrificial anode. This means the zinc layer will corrode before the steel layer beneath it. Various industries and applications widely use galvanized steel due to its low cost, long life, and resistance to mechanical damage.

Galvanized steel offers several advantages:

Less expensive than stainless steel and does not require additional surface treatments or coatings.
It has a lengthy lifespan of more than 50 years in average environments and more than 20 years in severe water exposure.
The galvanization process controls the coating thickness and quality, making it reliable and consistent.
As a result of the zinc coating creating a metallurgical bond with the steel, its mechanical properties are improved, rendering it solid and long-lasting.

Some galvanized steel applications are:

Construction — People use galvanized steel for roofing, walling, foundations, and structural components such as beams, columns, and frames.
Automotive — Manufacturers use galvanized steel to make body panels, chassis, and other parts that must withstand corrosion and maintain strength.
Solar — Mounting systems, frames, and supports for solar panels are made with galvanized steel, capable of enduring severe weather and UV exposure.
HVAC — Ductwork, pipes, and fittings for heating, ventilation, and air conditioning systems often utilize galvanized steel due to its ability to prevent both condensation and corrosion.
Agriculture — Galvanized steel is used for fencing, silos, greenhouses, and animal shelters. This is because it can resist animal damage and chemical exposure.

Solar Trackers: Where Steel Shines

Image Attribution: https://www.freepik.com/free-photo/photovoltaics-solar-power-station-energy-from-natural_10896368.htm#page=2&query=galvanized%20steel%20in%20solar%20trackers&position=28&from_view=search&track=ais&uuid=965b391b-330b-401a-9427-5fa200bf38bd

Some […]

8 03, 2024

Processing Steel in the U.S. – Metal Forming 101

jane2024-03-13T17:10:30+00:00March 8th, 2024|News Blog|

Metal forming is a process vital in the US steel processing industry. Renowned for its capacity to mold complex shapes and structures, it’s a process embraced by steel processors throughout North America for its capability to generate a wide array of essential products, from precision automotive parts to critical aerospace components.

Metal forming requires skilled professionals and advanced machinery, which is where steel service centers come in. These centers are the go-to source for metal processing, forming, and distribution, providing essential services that help transform raw materials into finished products.

What is Metal Forming?

Have you ever wondered how metals manufacturers create various shapes and sizes of metal parts? It’s thanks to the fascinating process of metal forming: the art of shaping a piece of metal into any desired shape. Various methods are involved in this process, from roll forming and bending to extrusion and forging.

The best part about metal forming is its efficiency and accuracy. With this technique, manufacturers can create large, sturdy metal parts with high precision. And that’s why it has become an indispensable part of the manufacturing industry today. Next time you observe a metal part, remember it was made using a specific process.

Metal Forming Process: The Basics

Metal forming is a captivating process that encompasses a diverse array of production techniques. From forging and casting to rolling and bending, there are countless ways to transform raw metal stock into a finished item. Regardless of the technique, manufacturers aim to create high-quality products that meet customers’ needs. So, whether you’re a metalworking expert or just curious about the industry, metal forming is worth learning more about!

Cold Working Process

In the cold working process, one applies force to reshape metal, changing its shape without adding or removing any material. This process can achieve the desired shape of the metal at room temperature.

Heat Treated Process

Metals can be changed in many ways to make them more robust, flexible, and wear-resistant. One way to do this is by heat treatment, a process of altering the physical or chemical properties of a metal through the use of heating or chilling, normally with extreme temperatures, to achieve the desired result or appearance. Heat treatment is a common method used by manufacturers to give metals intricate shapes that are impossible to achieve through simple bending. It can also make steel more flexible and last longer.

Five distinct metal-forming processes:

1. Roll Forming

Roll forming is a key manufacturing process that involves bending a long strip of metal, typically coiled steel, by passing it through consecutive sets of rolls. Each pair of rolls performs a part of the bend until the metal achieves the intended cross-sectional profile. This method is versatile, allowing for the creation of various shapes and sizes at room temperature.

The process allows for manipulation of metals to enhance their physical or mechanical properties, achieving […]

14 03, 2022

Metals Processing: Advantages of Cold Rolled Steel

Cara2022-08-05T16:30:32+00:00March 14th, 2022|News Blog|

There are many steps required in metal processing in order to achieve a high-quality product. American steel processor, National Material Company (NMC), believes there can be no exception to this rule. Steel is an alloy that is a mixture of both iron and carbon and it is durable, sustainable, and highly desired by many industries. Formal specifications and different grades of steel can affect the performance and use of the metal, but there are additional techniques within the metals’ processing that can alter the strength and finish. In this article, we will focus on one technique known as cold rolling.

Engineers and designers alike must decide on the type of metal they will need to begin work on their projects. Cold rolled steel for many reasons might be the ideal metal. “Cold rolled” refers to the process the steel undergoes before becoming the final product. The temperature is not what we may consider “cold.” Instead, the entire process occurs at room temperature and involves applying great pressure to the steel. However, this does not mean cold rolled steel never experiences its recrystallization temperature. In fact, cold rolled steel endures extreme temperatures and compression rollers just like hot rolled steel. Cold rolled steel simply undergoes more processes once it has cooled down to get exact dimensions and better surface qualities. In many cases, steel may undergo processes like rolling, turning, grinding, and polishing. Each one gives the steel a unique finish.

There are many advantages of cold rolled steel, such as increased strength. (Read about Advanced High Strength Steel, or “AHSS” here.) The compression of the steel at room temperature hardens the strain, giving the metal significant strength when compared to other types of steel. That being said, the steel is not needlessly thick to create this strength. Cold rolling allows for tighter tolerances not found within other steel manufacturing. In other words, the metal will have thinner walls without sacrificing integrity.

One of cold rolled steel’s most desirable aspects is its aesthetics. The cold rolling process enables metal processors like National Material Company to improve the surface finish. It leaves a smooth surface with few imperfections that are ideal if a project requires visual appeal. An excellent surface is great not just for its beauty, however. Cold rolled steel is used in the construction of bridges due to fewer visible surface flaws.

Additionally, cold rolled steel is ideal for projects that require more precision and need to be durable. Bars created with this technique have well-refined edges, and tubes are very straight with excellent concentric uniformity.

Cold rolled steel can be found across many industries today. It is used in parts for home appliances, roof and wall systems, metal furniture, aerospace structural members, and a wide scope of applications too numerous to list. Despite the many steps within the cold rolling process, cold rolled steel has a short manufacturing time and can be delivered promptly so customers can begin work on their projects quickly.

National Material Company […]

8 07, 2021

Sustainable Steel Industry: Build Using Steel

Cara2021-07-08T17:15:17+00:00July 8th, 2021|News Blog, NMC Media|

The steel industry, as one of the globe’s premier industries in size and history, has taken its place of leadership in transforming itself towards sustainability. Previously identified as a smokestack industry, the steel industry has introduced new technologies and practices in becoming a green industry of sustainable steel.

Elon Musk has stated that environmental concerns “supersede political parties, race, creed, religion, it doesn’t matter. If we do not solve the environment, we’re all damned.” Or as Cameron Sinclair put it, “For 90 percent of the world, sustainability is a matter of survival.” For historian Thomas Fuller, the idea is very simple, “We never know the worth of water ‘til the well is dry.”

One way to see the huge strides the steel industry has taken is by looking at structural steel used in green construction. In particular, the “wood versus steel debate” sheds light on all the different aspects that need to be accounted for when considering sustainability and carbon neutrality.

For example, care must be taken to examine all the details involved with a product’s complete lifecycle. The extraction, manufacturing, and transportation of the materials must be calculated, but also the longevity, disposability, and reusability. Furthermore, all derivative processes must be considered. If the electricity used in steel plants is solar or wind energy, the steel industry becomes more sustainable without directly changing itself, just by modifying tangential processes. The same goes for the wood industry. Not all forest management practices are created equal, and the care taken in logging and replanting trees can radically change the sustainable nature of a material like wood.

By paying attention to all these details, the structural steel industry has decreased its carbon footprint per ton by 36%, lowered energy intensity per ton by 31%, and decreased greenhouse gas emissions per ton by 45%.

One of the most promising aspects of modern American steel processing is recycling, with steel being 100% recyclable. As reported by Architect Magazine, “The American Institute of Steel Construction estimates that 98% of structural steel from demolished buildings is recovered and recycled into new steel products. As such, domestically produced structural steel, which comes from electric arc furnace (EAF) mills, boasts a recycled content of 93%.” Because of steel’s longevity, in fact, one of the major bottlenecks in steel recycling is that, despite 98% of structural steel being recycled, finding enough scrap globally for the potential output of electric arc furnaces can be a problem.

Through innovation and design, the steel industry hopes to reach the ultimate goal: carbon neutrality. It is a fitting goal for an industry with a trajectory as important as steel. If we indeed turn this next century into the “Green Century,” the innovators of our times will become the heroes of the future. That, NMC believes, is a goal worth fighting for.

At NMC our steel slitting, cold rolled steel, hot rolled steel, and all our steel processes aim to continue the tradition of […]

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