The road ahead: how stainless steel redefines the future of the automotive industry

The notion of the future easily takes the imagination soaring among the tips of peculiar skyscrapers while dodging crisscrossing lines of sleek aerial vehicles. In fact, a flying car might just be the most classic symbol of life in the future. Regardless of the accelerating technological advancement, it is relatively fair to say that flying cars as standard transport are not quite around the corner.

However, in a sense, the future is already here in the form of stainless steel. From the point of view of Markus Buckner, Head of Strategic Market Mobility & Urbanization at Outokumpu, the future is visible for at least the coming decades. Interestingly, stainless steel can enable new solutions and even make a comeback in applications where it has been deemed a thing of the past.

Stainless steel offers both a current and growing competitive advantage to the automotive industry

Stainless steel has long been a staple in specific automotive applications, such as exhaust systems, where its durability and heat resistance are unparalleled. However, as the industry has shifted towards electric vehicles (EVs) and hydrogen-powered cars, the role of stainless steel is poised to expand significantly. "Stainless steel will remain state-of-the-art for exhaust systems and could become more prevalent in new applications, especially as we see changes in battery technology," Buckner notes.

Recent developments have seen a downshift in the demand for EVs in some market areas, which has led certain manufacturers to reconsider their plans. However, Buckner is adamant that at least the near future will still consist of already existing power sources and their further development.

 "The future will be supported by battery electric vehicles (BEVs), fuel cells, and traditional exhaust systems, with BEVs and fuel cells gradually increasing in prevalence. Meanwhile, exhaust systems will likely remain stable without significant growth or decline beyond 2030, mainly pushed by the current biofuel discussion.”

One of the critical advantages of stainless steel is its heat resistance, which makes it an ideal choice for components like battery trays in EVs and fuel cells in hydrogen cars. “This also benefits the safety aspect of future cars. With a melting point approximately twice as high as that of aluminum, stainless steel offers superior fire safety,” Buckner points out.

Stainless steel can change the landscape of automotive materials

Like most industries, the automotive sector is under increasing pressure to reduce CO₂ emissions. Based on scientific research, more should be done in shorter and shorter time to prevent climate change, and this direction is not likely to change any time soon.  

As one outcome, aluminum, a traditional go-to for many applications, is becoming a concern and thus less attractive due to its lower thermal stability and a shortage of recyclable scrap material. This shift opens new opportunities for stainless steel, which can contribute to sustainability efforts in many ways. 

"Despite being denser, stainless steel can reduce the thickness of parts without compromising strength, necessitating less material used and thus cutting emissions and costs,” Buckner notes. “With the sustainable production methods of Outokumpu and the closed-loop recyclability of the material, stainless steel enables better sustainability in manufacturing but also in the whole lifecycle of a vehicle," he continues.

Overcoming the obstacles for future innovation

The future of stainless steel in automotive manufacturing and efforts in making vehicles even safer, more efficient and more sustainable largely depends on overcoming entrenched industry biases.

"The aluminum lobby is strong, and many in the automotive industry are still inclined to stick with familiar materials. However, as we see advancements in battery technology and the rise of new powertrain systems like hydrogen fuel cells, the benefits of stainless steel will become increasingly hard to ignore,"

Buckner states.

Moreover, the future rise of car-sharing services could further boost the use of stainless steel in vehicles. "As shared mobility becomes more common, the demand for hygienic and easily cleanable surfaces will grow, which will likely make stainless steel more prevalent in consumer vehicles," Buckner predicts.

Looking ahead, stainless steel could become more common in areas where it is already utilized, such as crash performance parts and even vehicle outer bodies. Buckner highlights the potential for using stainless steel in "origami-like" folding techniques, which could eliminate the need for hot stamping and reduce CO₂ emissions.

"If we succeed in demonstrating the benefits of folding stainless steel, it could see a resurgence as an outer layer material. For this purpose, it was used already in the 1930s by some American car manufacturers and even more famously in Lincoln Continental and Ford Thunderbird in the 60s, not to mention DeLorean and Cybertruck," the expert points out.

Shaping the wheels of tomorrow with stainless steel

As we can see, stainless steel and its innovative development can not only enable completely new solutions but also rethink the old. "Thanks to the development of different methods and steel grades, it is entirely possible that stainless steel will make a comeback in, for example, the wheel rims of future cars," Buckner suggests.

The future of the automotive industry is uncertain, particularly with rapid advancements in battery technology, the utilization of hydrogen being somewhat in its infancy and shifts taking place in environmental regulations. However, stainless steel is well-positioned to play a crucial role in this evolving landscape. Through improved safety features, reduced environmental impact, and innovative design possibilities, stainless steel offers a promising path forward for car manufacturers.

"Stainless steel is more than just a material—it's a solution to many of the challenges the automotive industry will face in the coming decades. From safety and sustainability to aesthetics, it has the potential to redefine how we design and build vehicles,"

Buckner depicts.

As the automotive industry navigates the complexities of the 21st century, integrating stainless steel into more aspects of the future of vehicle design and manufacturing seems not only likely but necessary.