Tata Steel has developed an innovative new product for automotive manufacturers in response to market requirements for stronger and lighter steels.

The new product, DP1000HY-GI*, is a high-yield, ultra high-strength steel which combines strength and formability and allows manufacturers to make lighter components without altering their production facilities. The material is ideally suited for the crash-protection structure of a vehicle. Tata Steel is one of a very small number of steelmakers to be able to offer this innovative product, which can reduce a component's weight by up to 15%.

Tata Steel worked closely with automotive manufacturers to develop this high-strength steel, which can be processed by manufacturers' existing machinery – a critical consideration in its development.

The high-yield strength of DP1000HY steel, which allows the material to endure high stress during deformation and therefore absorbs more crash energy, is most suitable for making components such as A and B pillar reinforcements, sills, door beams and cross members.

The strength of the new steel allows designers to reduce material consumption, offering the potential of an eight to 15 per cent decrease in component weight depending on the steel grade being replaced. Its superior formability makes it suitable for creating relatively complex shapes, while its optimal energy absorption capability is ideal for making crash-relevant components.

DP1000HY also fulfils the requirements of the German association of car manufacturers, the Verband der Automobilindustrie (VDA), ensuring it meets the stringent safety requirements demanded by vehicle manufacturers globally.

Sander Heinhuis, Tata Steel's European Marketing Manager for Automotive, said: "The safety of occupants is the most important consideration when designing a vehicle, but with the ever-increasing pressure to reduce carbon emissions, it is vital manufacturers use materials which are as light as possible.

"Through the development of DP1000HY, Tata Steel has combined high yield, ultra high strength and formability, allowing automotive manufacturers to reduce the thickness of the steel they use. They can consequently achieve impressive crash-protection and at the same time have the option of reducing weight. We are working closely with our customers to demonstrate the benefits they can achieve from using this product."

DP1000HY steel incorporates carbon and manganese to increase its strength and hardenability. It is available in a range of dimensions, in thicknesses of up to 2mm and widths of up to 1,400mm. It is finished with a hot-dipped galvanised coating, offering good corrosion protection and making it a cost-effective body structure solution.

Production of DP1000HY started last month. Tata Steel will process orders for new and existing customers from its production facility at IJmuiden in the Netherlands. This latest addition to Tata Steel's range of dual-phase steels means the company can now offer three strength levels of 600, 800 and 1,000 megapascals.