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In recent years there is an increasing demand for safer, more fuel efficient and more durable vehicles while reducing cost of ownership. To meet these demands, a new generation of zinc-magnesium alloyed hot dip galvanized steel has been developed. The product has recently been introduced for exposed panels. The innovative zinc-magnesium alloyed coating of this steel increases corrosion protection, allowing for thinner coating layers and therefore a potential for lighter parts. More important the properties of this new coating improve production performance by reducing tool pollution and galling behavior during processing in the press shop. This new steel product allows OEMs to meet the expectations of today’s automotive market. When taking into account cost critical performance in the press shop, the zinc-magnesium alloyed coating provides a clear advantage over conventional coatings, offering up to a 30% reduction in tool pollution.

In May 2000, the UltraLight Steel Auto Closure (ULSAC) Consortium unveiled a lightweight frameless steel door design that achieves 42 percent weight savings over the average benchmarked (1997 model year vehicles) frameless door and 22 percent savings over the lightest benchmark, a framed door. ULSAC was commissioned by this international consortium of 31 sheet steel producers to assist their automotive customers with viable lightweighting steel solutions. The ULSAC design and engineering team, Porsche Engineering Services, Inc. (PES), Troy, Michigan USA, accomplished this significant weight savings by using high and ultra high strength steels, combined with technologies such as tailored blanks and hydroforming. The door outer panel of this first round of demonstration hardware is made of stamped 0.7 mm Bake Hardenable (BH) 260 sheet steel.