SFP WORKS, LLC — Department of Energy SBIR Phase II: 02b

Description

The Department of Energy (DOE) has pursued multiple strategies for making vehicles lighter and more fuel efficient. Past efforts have focused on either developing technologies to replace heavy steel components or using high-strength steels to reduce the amount of steel needed for the same load-bearing capacity. However, these techniques have proved problematic because the former requires expensive exotic materials and expensive factory retooling for manufacturers, while the latter involves using high strength steels that require expensive alloying elements or are brittle and unsuitable for automotive applications. SFP Works has developed a novel heat treating process to create low-cost, very high-strength steel known as Flash Processing or Flash Bainite that uses a thermal cycle of less than 10 seconds to create a ductile and weldable steel well suited or the automotive industry. In this proposed effort, SFP Works will a) further develop SBIR Phase I proven methods by showing commercial feasibility of room temperature forming/stamping of Flash Bainite 1500MPa and b) create complete process parameterization and weld schedules for multiple Flash alloys for full scale commercialization leading to a weight/cost savings of 33-50% of the metal in a vehicle. In Phase I, SFP Works formed Flash Processed steel for automotive structural applications and conducted preliminary evaluations with an automotive OEM to determine the suitability of those parts for automotive applications. In the Phase II effort, SFP Works will define Flash processing specifications and characterize the resultant material in grades, compositions, and formats relevant to automotive applications. SFP Works will also conduct application trials, experiments, and evaluations with relevant automotive OEM and suppliers in order to validate characterization data. Flash Processed steel will provide Americans with lighter more fuel efficient vehicles that also perform as well, or better, in all passenger protection safety tests. Additionally, Flash Processed steels could allow for cranes with longer boom lengths and increased lifting capacity, and farm machinery, military equipment, line pipe, and pressure vessels that are lighter and easier to transport yet just as durable.