“It’s not just about this one solution. It’s a blueprint for tackling future challenges with the same precision and innovation.”
Gary Black, Vice-President of Advanced Manufacturing at ArcelorMittal
FORGING THE FUTURE
HOW ArcelorMittal AND ANDRITZ REINVENTED AUTOMOTIVE MANUFACTURING
A partnership between ArcelorMittal and ANDRITZ has revolutionized how vehicle components are made, combining innovation with precision to deliver lighter, safer, stronger, and more sustainable parts.
“This looked good on paper but was a technical Everest,” recalls Gary Black, Vice-President of Advanced Manufacturing at ArcelorMittal Tailored Blanks North America. The challenge? Redefine automotive manufacturing by creating complex, multi-piece door rings. The solution came in the form of SOURING, a custom laser welding system developed through an intense, multi-year collaboration between ArcelorMittal and ANDRITZ.
REINVENTING THE DOOR RING
In the quest for cleaner, more efficient vehicles, weight reduction has become essential. The door ring – a structural component critical for vehicle crash safety – was traditionally stamped from single steel sheets, making it heavy and wasteful. “Such designs were outdated and inefficient,” says Black. The idea was to use laser welded blanks (LWBs), combining steel of varying thicknesses into a single optimized component. This would cut weight without compromising crash safety, especially crucial for electric vehicles where battery protection is key.
The welding process required unprecedented precision to join materials seamlessly along complex geometries. ANDRITZ Soutec, known for its expertise in laser welding, emerged as the ideal partner.
ANDRITZ’s SOURING laser welding system at ArcelorMittal produces lightweight automotive door rings, achieving 30% weight reduction
through innovative tailor-welded blank technology
A BENCHMARK FOR TACKLING FUTURE CHALLENGES
The new system redefines vehicle component manufacturing through the precise production of tailor-welded blanks. Door rings now achieve up to 30% weight reduction, improving fuel efficiency and extending EV range.
Furthermore, the technology streamlined production significantly: parts for a typical double door ring decreased from 26 to 8, spot welds were reduced from 310 to 66, and floor space requirements dropped by up to 40%. The system welds at 10 meters per minute with scrap rates below 2%, delivering industrial-scale practicality alongside innovation.
The door ring design delivers exceptional crash performance by creating a continuous load path for energy transfer during collisions. The 2017 Chrysler Pacifica, using this design, became the first minivan to earn the IIHS Top Safety Pick Plus award. This underscores the critical role laser-welded structures play in protecting passengers while also making vehicles more sustainable.
© ArcelorMittal
Innovative laser-welded door rings combine enhanced crash protection through continuous energy transfer and weight reduction, advancing both passenger safety and vehicle sustainability.
THE ROAD AHEAD
The technology extends beyond door rings to underbody structures and reinforcements. Currently, 36% of battery electric vehicles in North America use parts manufactured with this system. The technology’s principles make it valuable for the aerospace and construction sectors as well. Future enhancements include automated controls and real-time monitoring to further improve efficiency and reduce waste.
The collaboration between ArcelorMittal and ANDRITZ has set new standards in automotive manufacturing, delivering lighter, stronger, safer, and more sustainable vehicle components.
“It’s not just about this one solution. It’s a blueprint for tackling future challenges with the same precision and innovation,” says Black. What started as an idea is now the basis for a sustainable transformation, demonstrating the power of strategic collaboration.