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[Due to the increasing size of the archives, each topic page now contains only the prior 365 days of content. Access to older stories is now solely through the Monthly Archive pages or the site search function.]

2018 Chevy Equinox drops almost 400 lbs; about 10% of mass

June 21, 2017

The 2018 Chevrolet Equinox SUV has dropped nearly 400 pounds (181 kg)—approximately 10% of its mass—compared to its predecessor. Combined with this weight loss, the all-new body was designed and optimized for top safety ratings.

The 2018 Equinox’s body structure design was optimized with a mixed-material strategy for strength and low weight. More than 80% of the Equinox’s body structure is composed of high-grade steel materials, with high-strength steel comprising nearly 20%.

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Warwick team develops new technique controlling brittle stages in production of high-strength, lightweight steels

A team at the Warwick Manufacturing Group (WMG), University of Warwick (UK) has developed a new processing route which allows low-density steel-based alloys to be produced with maximum strength, while remaining durable and flexible—something which has been largely impossible until now.

The development could enable the production of high-strength, lightweight steels on an industrial scale, and could lead to safer, greener, more fuel-efficient and streamlined cars. A paper on the research is published in the journal Acta Materialia.

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Teijin develops first polycarbonate-resin pillar-less automotive front window; used in EV

June 19, 2017

Teijin Limited has developed the first polycarbonate (PC)-resin pillar-less automotive front window for use in the Tommykaira ZZ, a sporty electric vehicle (EV) produced by GLM Co., Ltd., an EV manufacturer launched by Kyoto University.

Automotive front windows must satisfy a variety of regulations, including for light transmission, abrasion resistance and crash safety. While A-pillars provide protection in the event of a frontal collision, thicker A-pillars obstruct the driver’s view. Japan’s new automotive safety standards will require plastics-glazed windows in models released from July to offer enhanced resistance to abrasion and weather.

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DOE: automotive use of lightweight materials has increased over last 20 years even as weight increases

June 06, 2017

As automakers strive to improve fuel economy, they have turned increasingly to lightweight materials to reduce overall vehicle weight—even though the average weight of materials in North American light vehicles has increased from 3,694 lbs (1,675.57 kg) in 1995 to 3,994 lbs (1,811.65 kg) in 2014, according to figures from the US Department of Energy (DOE).

Use of regular steel has declined by more than 250 lbs (113.4 kg) per vehicle from 1995 to 2014 from 1,630 lbs (739.36 kg) to 1,379 lbs (625.5 kg). At the same time, the use of high- and medium-strength steels has doubled, increasing by 325 lbs (147.42 kg) per vehicle—from 324 lbs to 649 lbs (294.38 kg).

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Brunel, Sarginsons developing high-performance cast aluminum alloys for energy-absorbing structures; better bumpers without steel

May 22, 2017

The Brunel Centre for Advanced Solidification Technology (BCAST), a global leader in metallurgical casting research, is working closely with foundry partner Sarginsons Industries and others on the development of high-performance cast aluminum alloys as part of the Lightweight Energy Absorbing Aluminium Structures for Transport (LEAAST) project.

Advanced aluminum automotive body designs still depend on steel for bumper beams; in rail applications, steel-based crash systems predominate. LEAAST is working to design, manufacture and demonstrate lightweight aluminium systems based on the use of a novel high strength aluminium extrusion alloy that can replace the incumbent steel systems while providing at least a 25% weight reduction using alloys formulated from recycled end of life scrap.

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Researchers develop microwave-driven, energy-efficient process for magnesium production

May 18, 2017

Magnesium has the highest strength-to-weight ratio of the structural metals; as such, it is attractive for use in transportation as well as in sustainable battery technologies (e.g, earlier post). However, its current production through ore reduction using the conventional Pidgeon process emits large amounts of CO2 and particulate matter (PM2.5).

Now, researchers at the Tokyo Institute of Technology and colleagues at Oricon Energy have developed a novel Pidgeon process driven by microwaves to produce Mg metal with less energy consumption and no direct CO2 emissions. In an open-access paper on the work published in the journal Scientific Reports, the team reports that the microwave Pidgeon process made it possible to produce Mg with an energy consumption of 58.6 GJ/t, corresponding to a 68.6% reduction when compared to the conventional method.

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Audi puts steel back in the new A8

May 12, 2017

The new Audi A8, scheduled for release in 2018, features a multi-material body structure (earlier post) consisting of more than 40% steel. That’s a marked turnaround from the all-aluminum body-in-white which Audi developed for the A8 in 1994, in which steel was essentially used for the B-pillars alone, and accounted for about 8% of the body structure.

Since then, steel has evolved significantly. Steel’s strength has multiplied by almost 10 times over the past 20 years, from 270 to 2000 MPa tensile strength. More than 80 new steel products are under development at steelmaker ArcelorMittal, with an automotive steel grade portfolio of almost 200 unique steel grades, half of which were introduced in just the past decade.

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Toyota using Mitsubishi Rayon’s carbon fiber SMC for hatch door frame of new Prius PHV

April 24, 2017

Mitsubishi Rayon (MRC) (which is now consolidated into Mitsubishi Chemical, along with Mitsubishi Plastis and the former Mitsubishi Chemical) recently announced that its carbon fiber sheet molding compound (SMC) has been adopted for the rear hatch frame of the new Toyota Prius PHV. SMC is a form of thermoset chopped fiber composite; glass fiber reinforced SMC is already commonly in use in the automotive industry.

SMC developed by MRC is a type of intermediate material for CFRPs and a sheet-shaped material in which carbon fibers cut into several-centimeter lengths are dispersed in resin. The SMC can be processed into components in a short period of time—roughly 2 to 5 minutes—by press molding. In contrast to prepreg intermediate materials (uncut carbon fiber fabric impregnated with resin), this SMC features high formability for molding complicated shaped parts.

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DOE SBV Pilot selects 38 small business for labs partnerships; 2 fuel cell and 4 vehicle projects

The US Department of Energy’s (DOE) Small Business Vouchers (SBV) Pilot has selected eight DOE national labs for collaborations with 38 small businesses in the third round of funding. Among these are two projects in the fuel cells area and four projects in the vehicle area. Other projects address advanced manufacturing, bioenergy, buildings, geothermal, solar, water and wind technologies.

In the first two rounds of the program, 12 DOE national labs received funding to partner with 76 small businesses. With the latest announcement, SBV will have awarded approximately $22 million to support partnerships between 114 US small businesses and the national labs.

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Next-gen Audi A8 introduces new four-material space frame; light weight and rigid

April 06, 2017

For the next generation of the Audi A8, an intelligent mix of four materials—aluminum, steel, magnesium and carbon fiber-reinforced polymer (CFRP)—is being used for the first time in the weight-bearing body structure—more materials than in any of the brand’s previous production models.

The resulting low weight and impressive rigidity—the upcoming flagship’s torsional rigidity surpasses the predecessor model’s rigidity value by up to 24%—from the multi-material construction of the Audi Space Frame (ASF) offer greater performance, efficiency and safety.

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AAM develops new axle technology; lighter, more efficient for up to 1.5% better fuel economy

March 30, 2017

American Axle & Manufacturing (AAM) has developed completely new, significantly improved axle technology. QUANTUM driveline technology is scalable across a wide range of vehicle segments and provides substantial advantages regardless of vehicle size: reduced mass, increased power density, improved noise vibration and harshness (NVH) and fuel efficiency gains in a more compact system package. The combined additional efficiency and weight reduction can deliver 1% to 1.5% improved vehicle fuel economy, AAM said.

QUANTUM offers a 20% increase in power density along with a minimum 30% mass reduction at the same torque capacity. For a heavy-duty pickup, QUANTUM provides more than 100 lbs. of vehicle weight savings, said Phil Guys, AAM vice president and chief technology officer. “It is significantly more efficient without any reduction in performance.

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New Lotus Elise drops even more weight; Sprint edition at 798 kg

March 20, 2017

Lotus has unveiled a significant update for the Lotus Elise ahead of its arrival in showrooms this spring. The new Sprint edition features the biggest weight cut to the car since the introduction of the first-generation Elise. The Sprint edition of the Lotus Elise has removed 41 kg (90.4 lbs) from the previous model, to reach a benchmark dry weight of just 798 kg (1,759 lbs).

Integrating a new front and rear aesthetic with Lotus’ established design language, this latest Elise also receives a wide range of cabin enhancements, including the lightweight open-gate gear select mechanism first introduced on the Lotus Exige Sport 350. The Sprint is available in both the 1.6-liter naturally aspirated and 1.8-liter supercharged versions.

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Novelis enters supply agreement with NIO to provide aluminum solutions for next-gen EVs

March 16, 2017

Novelis, the world leader in aluminum rolling and recycling, has expanded its automotive supply capabilities by signing an agreement with EV company NIO (earlier post), to provide innovative aluminum solutions for its fleet of smart, high-performance, premium electric vehicles. NIO will use Novelis Advanz aluminum alloys to create a wide range of structural components and parts for its aluminum-intensive NIO electric SUV models to be launched over the next five years.

The NIO partnership marks Novelis’ first major commitment in the premium electric vehicle space. Supply for NIO will come from Novelis’ Changzhou plant, China’s first facility dedicated to manufacturing heat-treated automotive sheet. The plant is an example of Novelis’ long-term commitment and capability to supply product in Asia for auto manufacturers based in that region and globally.

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Magna and Ford developing prototype carbon fiber composite subframe; mass reduction of 34%

March 14, 2017

In pursuit of lower vehicle weight to reduce emissions and improve fuel efficiency, Magna International Inc., in cooperation with Ford Motor Company, developed a prototype carbon fiber composite subframe which reduces mass by 34% compared to making a stamped steel equivalent. The subframe is a key part of a vehicle’s structure, typically providing a place to attach the engine and wheels while also contributing rigidity and crash management.

By replacing 45 steel parts with two molded and four metallic parts, the prototype subframe achieves an 87% reduction in the number of parts. The moldings are joined by adhesive bonding and structural rivets.

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IACMI launches project to optimize resins and sizings for vinyl ester / carbon fiber composites; targeting automotive adoption

March 13, 2017

The Institute for Advanced Composites Manufacturing Innovation (IACMI), a Manufacturing USA institute driven by the University of Tennessee, Knoxville and the US Department of Energy, in partnership with Ashland, Zoltek, Michelman, University of Dayton Research Institute (UDRI), JobsOhio, and Michigan State University (MSU) has launched a project focused on the optimization of vinyl ester resins and fiber sizings for the fabrication of carbon fiber composites.

The effort will identify styrene-free prepreg formulations with longer room temperature shelf life, shorter cycle times, and reduced cost. Advancements in these areas will increase productivity, decrease scrap and material costs, and enable adoption into the automotive industry.

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Teijin develops new hard-coating technology for automotive plastics glazing

March 10, 2017

Teijin Limited has developed a new hard-coating technology that can be applied evenly on large or complex-shaped automotive windows made of resin to achieve the same level of abrasion resistance as glass windows and double the weather resistance of conventional plastics glazing.

Teijin initially will produce small-lot samples of actual windows for selected car models at a pilot plant in Matsuyama. Going forward, it will gradually verify production technologies for the manufacture of a wider range of windows on a mass-production basis, aiming at an early launch of full-scale commercial manufacturing operations.

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Ford testing 3D printing of large-scale parts using Stratasys Infinite Build 3D printer

March 09, 2017

Ford Motor Company is exploring how large-scale one-piece auto parts, such as spoilers, could be printed for prototyping and future production vehicles, as the first automaker to pilot the Stratasys Infinite Build 3D printer.

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GKN Driveline develops new lightweight propshaft for Audi Q5; more compact, lighter, more efficient; MLB Evo

March 02, 2017

GKN Driveline created a new lightweight, high-speed propshaft joint for the all-new Audi Q5. The PVL joint is smaller, lighter and more refined than predecessor technology, and represents a bespoke solution by GKN engineers to create a more compact joint. Its outer diameter is reduced by 7mm, representing an 8% reduction in the width and height of the space it occupies in the driveline.

The smaller joint is also 350g lighter, representing a 23% weight reduction, yet there is no negative impact on torque capacity. With a smaller rotating mass, the PVL joint improves performance and efficiency, and helps to lower vehicle emissions.

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Strong honeycomb cargo shelf in new Ford EcoSport SUV made of recycled paper; 6lb floorboard holds ~700 lbs of cargo

February 18, 2017

The adjustable cargo floorboard in the all-new 2018 Ford EcoSport is made of high-strength 100% recycled paper honeycomb. Constructed from all-natural paper and water-based glue, the six-pound honeycomb floorboard is both eco-friendly and strong enough to handle nearly 700 pounds of cargo across its 38.5-inch by 25.25-inch surface.

Ford introduced the EcoSport for North America in November 2016 (via the first Snapchat reveal). The EcoSport is intended to combined space-saving convenience, SUV capability and connectivity. The adjustable floorboard will debut as an all-new feature when EcoSport arrives early next year.

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Government of Canada awards $18.2M for aluminum autoparts and better Li-ion battery management

February 17, 2017

The Government of Canada is awarding a total of $18.2 million to two companies that have developed innovations with the potential to make cars lighter, more fuel efficient and, in the case of electric cars, better performing due to a longer battery life.

Astrex Inc. of Lakeshore will receive a repayable contribution of up to $17 million from the Federal Economic Development Agency’s (FedDev Ontario) Advanced Manufacturing Fund. The investment will enable Astrex, a manufacturer of auto parts, to establish a facility that produces lightweight, high-strength aluminum components. The parts manufactured at this plant will reduce fuel consumption and lower carbon emissions.

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FLAC project seeks 40-80% weight reduction in automotive components through 3D printing

January 22, 2017

Engineers at The University of Nottingham are developing lightweight automotive components using new additive manufacturing processes to boost vehicle fuel efficiency, while cutting noise and CO2 emissions as part of the Functional Lattices for Automotive Components (FLAC) project. FLAC aims to achieve significant weight reductions in mass (40-80%) and optimized thermo-mechanical performance in new vehicle components.

The Nottingham team will construct components using selective laser melting (SLM). SLM uses a 3-Dimensional Computer Aided Design (CAD) model to digitally reproduce the object in a number of layers. Each layer is sequentially recreated by melting sections of a bed of aluminium alloy powder using a laser beam. Layer by layer, the melted particles fuse and solidify to form novel structures that can be made up from complex lattices to provide a light-weight component. SLM helps increase functionality and lower the number of separate components in production. This significant mass saving cuts component costs and increases overall vehicle efficiency.

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Renault Trucks working with metal 3D printing to reduce engine size and weight

January 12, 2017

The Renault Trucks Lyon Powertrain Engineering department is developing metal additive manufacturing—i.e., 3D metal printing—as a future engine manufacturing process. The aim of this project is to demonstrate the positive impact of metal additive manufacturing on the size and weight of an engine, said Damien Lemasson, project manager at Renault Trucks.

Renault has designed a prototype DTI 5 4-cylinder Euro 6 step C engine for 3D printing production; the ability of additive manufacturing to produce complex forms resulted in a 25% reduction in the number of components in the DTI 5 engine—a total of 200 fewer parts. The Renault engineers have also manufactured rocker arms and camshaft bearing caps by metal 3D printing and successfully bench-tested these for 600 hours inside a Euro 6 engine.

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Daimler/Secar CRP hybrid struts receive AVK Innovation AWARD; intelligent material mix allows large-scale production

December 01, 2016

As part of a development project, researchers at Daimler AG and the Austrian CRP (carbon fiber reinforced plastics) applications specialist Secar Technologie GmbH have developed an innovative new CRP composite pultrusion process enabling carbon fibers and metal to be pultruded in profile form in larger volumes.

Pultrusion is a continuous molding process in which reinforcing fibers are saturated with a liquid polymer resin and then carefully formed and pulled through a heated die to form a part. Pultrusion results in straight constant cross section parts of virtually any shippable length.

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Divergent 3D partners with Altran to deploy 3D printing for car manufacturing

October 25, 2016

Divergent 3D, a manufacturing technology company focused on the automotive sector, has entered into a global development partnership with engineering research and development (ER&D) firm Altran. The partnership comes shortly following Divergent 3D’s signing a strategic partnership letter of intent with top-ten global automaker PSA Group. Divergent 3D is commercializing a software-hardware platform for manufacturing that leverages 3D metal printing.

Under the agreement, Altran has invested in Divergent 3D and will provide support to accelerate implementation and licensing of its manufacturing technology platform across the continent as part of Altran’s new vehicle architecture initiatives. Together, the companies intend to help automakers leverage 3D printing to unleash design innovation while cutting costs, time-to-market and environmental impact.

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2017 Audi Q7 now available with 2.0-liter TFSI turbo-charged four-cylinder engine; lower entry point to premium SUV

October 20, 2016

Audi of America is offering a new 2.0-liter TFSI four-cylinder engine on 2017 Audi Q7 models. This new model, when equipped with the 2.0-liter engine, is half a second faster on the 0-60 mph sprint; nearly 500 pounds lighter; and up to 22% more fuel-efficient than the previous generation Q7 3.0T V6.

With the 2.0 TFSI, Audi is creating a value proposition that makes entry into the luxury full-size SUV more accessible. The starting MSRP ($49,000) (Premium trim) is $5,800 below the current entry point of $54,800 for the Premium 3.0 TFSI; pricing for the 2.0L Premium Plus trim starts at $53,000 ($1,800 below the current entry point and $5,800 below the Premium Plus 3.0 TFSI). The specifications of the 2.0- and 3.0-liter engined cars are virtually the same except for the engine; the inlays which are a mix of aluminum and wood on the lower and upper dash vs all wood; and 18-inch wheels instead of 19-inch wheels.

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BASF and Hyundai Motor showcase RN30 concept at K Fair; new lightweight and performance materials

October 14, 2016

Hyundai Motor unveiled the RN30 high-perfromance concept at the Paris Motor Show in September. At the upcoming 2016 K Fair—the leading global trade fair for plastics and rubber—in Düsseldorf from 19-26 October, BASF and Hyundai will showcase some of the new lightweighting and high-performance materials technology that went into the car.

The RN30, jointly developed by BASF and Hyundai Motor Company, combines key solutions from the chemical industry with purposeful aerodynamic design and specialized high-performance technologies.

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CarboSax: new joint venture for more sustainable carbon fiber production forms in Germany

October 13, 2016

PD Glasseiden, a Germany-based producer of fiberglass; European Carbon Fiber GmbH; and the ForschungsCampus Open Hybrid LabFactory e.V., established under the auspices of the Lower Saxony Research Centre for Vehicle Technology at the TU Braunschweig and Volkswagen AG have formed a joint venture—CarboSax GmbH—to pursue developing, manufacturing and distributing more sustainable carbon fibers in Germany.

In the first step at a location in Chemnitz, Saxony, CarboSax will build a pilot line for the sustainable production of carbon fibers. The objective of this carbon fiber pilot line production is a significant reduction in production costs by 30% over currently available commercial carbon fibers. This cost reduction is required to further enable the use of carbon fiber in mass production in the automotive industry, mechanical engineering and wind power. An equal objective is a reduction of at least 50% in CO2 emissions from carbon fiber production.

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Kiel nanoscale-sculpturing makes metal surfaces strong, resistant, and multifunctional; multi-material joining

September 08, 2016

Researchers at the University of Kiel (Germany) have developed a new process—which they call “nanoscale-sculpturing”—for the surface preparation of metals.

Nanoscale-sculpturing, which is based on knowledge from semiconductor etching, turns surfaces of everyday metals into their most stable configuration, but leaves the bulk properties unaffected. Thus, nanoscale-sculpturing ensures stronger, reliable joints to nearly all materials, reduces corrosion vastly, and generates a multitude of multifunctional surface properties. An open-access paper on their work is published in the RSC journal Nanoscale Horizons.

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DOE HPC4Mfg program funds 13 projects to advance US manufacturing; welding, Li-S batteries among projects

August 31, 2016

A US Department of Energy (DOE) program designed to spur the use of high performance supercomputers to advance US manufacturing has funded 13 new industry projects for a total of $3.8 million. Among the projects selected are one by GM and EPRI of California to improve welding techniques for automobile manufacturing and power plant builds in partnership with Oak Ridge National Laboratory (ORNL).

Another one of the 13 projects is led by Sepion Technologies, which will partner with LBNL to make new membranes to increase the lifetime of Li-S batteries for hybrid airplanes.

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LeMond Composites licenses ORNL low-cost carbon fiber manufacturing process; transportation, renewable energy, & infrastructure

August 30, 2016

LeMond Composites, founded by three-time Tour de France champion Greg LeMond, has licensed a low-cost, high-volume carbon fiber manufacturing process developed at the US Department of Energy’s Oak Ridge National Laboratory (ORNL). (Earlier post.) The agreement will make Oak Ridge-based LeMond Composites the first company to offer carbon fiber produced by the process to the transportation, renewable energy, and infrastructure markets.

Invented by LeMond CEO Connie Jackson and a research team at ORNL’s Carbon Fiber Technology Facility (CFTF), the process is projected to reduce production costs by more than 50% relative to the lowest-cost industrial-grade carbon fiber.

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AK Steel introduces NEXMET family of next generation high strength steels for automotive lightweighting

August 22, 2016

AK Steel launched NEXMET, an new family of high strength steels for use in automotive lightweighting applications. These products are specifically designed to assist automotive original equipment manufacturers (OEMs) in meeting 2025 US Corporate Average Fuel Economy (CAFE) targets.

AK Steel’s NEXMET family of products will offer high strength, greater ductility (elongation), and improved formability solutions for a range of needs for structural and exterior automotive body lightweighting uses.

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IACMI, DuPont and Purdue partner on automotive carbon-fiber composites

August 18, 2016

The Institute for Advanced Composites Manufacturing Innovation, IACMI, in partnership with DuPont Performance Materials, Fibrtec Inc. and Purdue University, has launched the first project selected with a dual focus on decreasing the cost of manufacture and increasing design flexibility for automotive composites. Advancements in both areas can open up new opportunities and become an enabler for large-scale deployment of composite parts.

Multiple factors, including cost and design constraints, present barriers to the adoption of composites in high volume automotive applications. This new IACMI project will address both of these critical areas through a fundamentally different approach to the manufacturing of carbon fiber composites versus those currently in use today.

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CNT nanostiches strengthen laminated composites

August 03, 2016

A team from MIT and Saab AB has found a way to bond composite layers in such a way that the resulting material is substantially stronger and more resistant to damage than other advanced composites. Their results are published this week in the journal Composites Science and Technology.

The team reinforced aerospace-grade unidirectional carbon fiber laminate interfaces with high densities (>10 billion fibers per cm2) of aligned carbon nanotubes (A-CNTs) that act as nano-scale “stitches”. Such nano-scale fiber reinforcement of the ply interfaces has already been shown to increase interlaminar fracture toughness; the MIT researchers showed that laminate in-plane strengths are also increased via the technique.

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Pitt engineers using LLNL electron microscope to study rapid solidification of aluminum alloys

August 02, 2016

University of Pittsburgh engineers will utilize a unique transmission electron microscope developed and housed at Lawrence Livermore National Laboratory (LLNL) to better understand how microstructures form in metals and alloys as they solidify after laser beam melting.

Under a three-year, $500,000-grant from the National Science Foundation, Jorg Wiezorek, a professor of mechanical engineering and materials science at Pitt, and his team will continue to use the Lab’s dynamic transmission electron microscope (DTEM) to study the rapid solidification of aluminum alloys associated with laser or electron beam processing technologies, including welding, joining and additive manufacturing.

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Cadillac and ContiTech win 2016 Altair Enlighten Awards for innovation in automotive vehicle lightweighting

Simulation technology company Altair, together with the Center for Automotive Research (CAR), announced the winners of the 4th annual Altair Enlighten Award an award program created specifically to acknowledge innovation in vehicle weight reduction.

The winner of the OEM-focused Full-Vehicle category was GM for the 2016 Cadillac CT6, a vehicle 157 lbs (71 kg) lighter than the BFI (body frame integral) construction. For the Module category, which focuses on the achievements from within the automotive supplier base, the winner was ContiTech for its unique polyamide rear crossbeam for the 2016 Mercedes S-Class. The awards were presented during the 2016 CAR Management Briefing Seminars (MBS) in Traverse City, Mich.

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SMDI releases steel roadmap for automotive; Gen3 AHSS

Over the past 10 years, new steel innovations have reduced automotive component and sub-system mass by nearly 25%; some studies have shown mass savings up to 29% versus traditional mild steel benchmarks. The Steel Market Development Institute (SMDI)—a business unit of the American Iron and Steel Institute (AISI)—has now released its 2016 Steel Industry Technology Roadmap for Automotive.

The roadmap outlines the long-term technology needs to support future automotive material selection decisions with advanced high-strength steel (AHSS) including, optimized design, fuel economy, strength and durability, environmental performance and value.

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LLNL researchers build scalable ultra-lightweight and flexible 3D-printed metallic materials

July 21, 2016

Lawrence Livermore National Laboratory (LLNL) engineers have achieved unprecedented scalability in 3D-printed architectures of arbitrary geometry, opening the door to super-strong, ultra-lightweight and flexible metallic materials for aerospace, the military and the automotive industry.

In a study published in Nature Materials, the LLNL engineers report building multiple layers of fractal-like lattices with features ranging from the nanometer to centimeter scale, resulting in a nickel-plated metamaterial with a high elasticity not found in any previously built metal foams or lattices.

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