[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.]
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Lamborghini inaugurates new Advanced Composite Structures Laboratory carbon fiber research center in Seattle
June 21, 2016
Automobili Lamborghini celebrated the grand opening of its new Seattle-based carbon fiber research facility, the Advanced Composite Structures Laboratory (ACSL). Operating as an entity outside of the company's headquarters in Sant’Agata Bolognese, the ACSL is responsible for unlocking new potential in carbon fiber.
Seattle is a strategic location for the ACSL, particularly because of its collaboration with Boeing in working toward carbon fiber innovations that are beneficial in both automotive and aerospace applications. The grand opening of the new ACSL also marks the 30th anniversary of Lamborghini’s use of carbon fiber reinforced polymer in its vehicles.
Novelis commissions $120M finishing line for automotive aluminum sheet; importance of the closed-loop recycling program
May 26, 2016
Novelis, the world leader in aluminum rolling and recycling, celebrated the commissioning of its third CASH (Continuous Annealing Solution Heat) treatment finishing line for aluminum automotive sheet in Oswego, NY. Installed to support the production of stronger, lighter and safer vehicles, the $120-million CASH 3 line expands the company’s production to supply aluminum sheet for the body and cargo box of Ford’s 2017 F-150 SuperDuty pickups. The CASH 1 and 2 lines supply aluminum for Ford’s F-150. With the addition of the third CASH line in Oswego, Novelis has furthered its position as the leading automotive aluminum sheet supplier in North America.
The commissioning of the CASH 3 line also marks the expansion of the benchmark closed-loop recycling program—developed by Novelis, Ford and Penske—which processes roughly 25 million pounds of automotive aluminum scrap per month—more than enough to build 30,000 F-150 bodies. (Earlier post.) Recycled aluminum, which requires significantly less energy and water, avoids 95% of the greenhouse gas emissions associated with primary aluminum production.
DSD and Solvay partner on use of structural plastics for lighter and more efficient transmissions
Automotive engineering consultancy Drive System Design (DSD) and international chemical and advanced materials company, Solvay SA, have entered a development partnership to make the large scale use of structural plastic composites in transmissions a viable solution for future vehicles. DSD is contributing the transmission know-how while Solvay the materials expertise.
There is an immediate weight saving from substituting plastic materials for conventional metal castings but equally important is the potential for improved efficiency due to the greater inherent damping provided by polymeric materials, the partners said. This permits the use of gears that are much more efficient but would have unacceptable noise characteristics in a conventional casing.
Airbus APWorks unveils 3D-printed electric motorcycle; 35kg total, 6kg bionic structure frame
May 22, 2016
APWorks, a 100% subsidiary of Airbus Group, has unveiled the first 3D-printed motorcycle. Dubbed the Light Rider, the motorcycle is made using APWorks’ Scalmalloy material, and weighs only 35 kg (77 lbs). With a 6 kW electric motor powering it from zero to 80 km per hour in just seconds and a frame weighing a mere 6 kg (13 lbs), the world’s first 3D-printed electric motorcycle is 30% lighter than conventionally manufactured e-motorcycles.
Scalmalloy is one of the latest new materials developed by Airbus Group. It is a second-generation aluminum-magnesium-scandium alloy (AlMgSc), and was developed for high and very high-strength extrusions, offering exceptionally high fatigue properties. Specifically developed for additive layer manufacturing (ALM)-based production, the material combines high strength with an extraordinary level of ductility, making it an especially interesting material to use for highly solicited parts in lightweight robotics, automotive and aerospace applications.
ORNL team develops laser process for lower cost, more robust joining of carbon fiber and aluminum
May 20, 2016
Researchers led by a team from Oak Ridge National Laboratory (ORNL) have developed a new laser process that could make joining carbon fiber composites and aluminum for lightweight cars and other multi-material high-end products less expensive—as well as making the joints more robust.
The process would replace the practice of preparing the surface of the materials by hand using abrasive pads, grit blasting and environmentally harmful solvents. Using a laser to remove layers of material from surfaces prior to bonding improves the performance of the joints and provides a path toward automation for high-volume use.
Max Planck, MIT researchers develop new strategy for high-entropy alloys; overcoming the strength/ductility tradeoff
May 19, 2016
Researchers at the Max Planck Institute in Dusseldorf, Germany, and MIT have developed a novel strategy to design nanostructured, bulk high-entropy alloys (HEAs) (earlier post) with multiple compositionally equivalent high-entropy phases. The new approach is described in a paper this week in the journal Nature.
The result, says C. Cem Tasan, the Thomas B. King Career Development Professor of Metallurgy in MIT’s Department of Materials Science and Engineering, also challenges the conventional wisdom that improving the strength of a metal alloy is always a tradeoff that results in a loss of ductility.
ORNL exclusively licenses plasma processing technology for carbon fiber production to RMX Technologies; 75% less energy, 20% lower cost
May 13, 2016
RMX Technologies and the Department of Energy’s Oak Ridge National Laboratory have signed an exclusive licensing agreement for a new technology that significantly reduces the time and energy needed in the production of carbon fiber. Combing these benefits with a low-cost precursor currently in development, the result can be a carbon fiber product that is 40% less expensive to manufacture than current commercial products.
The ORNL/RMX plasma processing technology is a new approach to the oxidation stage of carbon fiber production in which polymer materials are oxidized (or stabilized) before carbonization. During oxidation, the thermoplastic precursor is converted to a thermoset material that can no longer be melted. Oxidation is the most time-consuming phase of the multistep carbon fiber conversion process.
Hemming of thin-gauge AHSS achieves 30% weight savings
May 12, 2016
Hemming is a forming operation which is used in the automotive industry to join two sheet metal panels together. During the process, the flange of the outer panel is bent over the inner one. It is commonly used to assemble the outer parts of a car, such as doors, hoods, trunk leads and fenders. The accuracy of the hemming operation is very important as it affects the surface appearance and thus influences surface quality
Novelis supplying aluminum for Cadillac CT6 in N America and China
May 10, 2016
Aluminum rolling and recycling leader Novelis announced that its aluminum is used in the new 2016 Cadillac CT6 body. The new mixed material vehicle construction featured in the Cadillac CT6 represents a first of its kind for General Motors (GM) in North America and China. (Earlier post.)
In North America, Novelis’ plant in Kingston, ON will supply GM’s Detroit-Hamtramck plant in Detroit, Michigan. Novelis’ plant in Changzhou, China will supply GM’s Shanghai plant, which will produce the CT6 manufactured locally in China.
NanoSteel and AK Steel deliver next-gen advanced high-strength steel to GM
April 21, 2016
NanoSteel, a leader in nanostructured steel materials (earlier post), announced the delivery of its first advanced high-strength steel (AHSS) to General Motors for initial testing. GM Ventures invested in NanoSteel in 2012. (Earlier post.)
Designed to provide automakers with a new standard in material performance, the sheet steel is poised to accelerate vehicle lightweighting initiatives focused on affordably meeting rising global fuel-economy regulations. Production of the material, targeted to the $100 billion-plus automotive steel market, is the result of a multi-year joint development program between NanoSteel and AK Steel Corporation—an industry-leading innovator in steel product development.
Outokumpu and Fraunhofer Institute develop lightweight stainless steel battery pack for EVs; up to 20% weight reduction
April 19, 2016
Finland-based stainless steel expert Outokumpu is working on lightweight stainless steel solutions for electric vehicles in cooperation with Fraunhofer Institute for Laser Technology ILT, in Germany. Their latest innovation is a new battery pack that combines several lightweight engineering technologies as well as new types of cooling and structural strategies.
The Forta H1000 fully-austenitic, ultra-high-strength stainless steel (an advanced manganese-chromium alloy) from Outokumpu enables the implementation of structural lightweight engineering initiatives, while providing a high level of safety.
BAIC BJEV in strategic cooperation with Dresden University of Technology for lightweighting technology
April 14, 2016
Beijing Electric Vehicle Co., Ltd. (BAIC BJEV), a subsidiary of BAIC, signed a strategic cooperation agreement with Dresden University of Technology (TUD) to create the Sino-German Automotive Light Weighting Technology Joint R&D Center. The two also entered into a letter of intent on the establishment of Sino-German Automotive Light Weighting Technology Engineering Center Co., Ltd. TUD Distinguished Senior Professor Werner Hufenbach was named chief scientist in lightweight technology for BAIC BJEV.
The Sino-German Light Weighting R&D Center will become the company’s fifth overseas R&D center. BAIC BJEV has been building its global R&D network in its core areas, i.e. electric and smart technologies, by establishing oversea R&D centers in Silicon Valley, USA; Aachen, Germany; Detroit, USA; and Barcelona, Spain. (Earlier post.)
PNNL team develops higher-strength, lower-cost titanium alloy aimed at improving vehicle fuel economy and reducing CO2 emissions
April 02, 2016
An improved titanium alloy—stronger than any commercial titanium alloy currently on the market—gets its strength from the novel way atoms are arranged to form a special nanostructure. For the first time, a team led by researchers at Pacific Northwest National Laboratory (PNNL) have been able to see this alignment and then manipulate it to make the strongest titanium alloy (hierarchical nanostructured Ti-185, or HNS Ti-185) yet developed. On top of the gains in strength, the new alloy benefits from a lower cost process.
In an open access paper published in the journal Nature Communications, the researchers note that that material is an excellent candidate for producing lighter vehicle parts, and that this newfound understanding may lead to creation of other high strength alloys.
ORNL seeking US manufacturers to license new carbon fiber process; reduces cost up to 50% and energy up to 60%
March 24, 2016
Researchers at the Department of Energy’s Oak Ridge National Laboratory have demonstrated a production method they estimate will reduce the cost of carbon fiber as much as 50% and the energy used in its production by more than 60%. After extensive analysis and successful prototyping by industrial partners, ORNL is making the new process available for licensing.
A detailed analysis of the new process compared to a published baseline for conventional carbon fiber production examined manufacturing cost of nine major process steps, starting with the precursor and pretreatment and finishing with surface treatment, sizing, winding, inspection and shipping. The analysis revealed the new process yields significant reductions in materials, capital and labor costs resulting in an overall manufacturing cost reduction of up to 50%. Details of the cost analysis will be shared with the prospective licensees.
Renault upgrades heavy-duty Trucks T for lower fuel consumption, higher payload
March 17, 2016
Less than three years after its launch and positive feedback from customers, Renault is upgrading the heavy-duty Trucks T to help it be even more cost efficient for its users. The 2016 version of the T benefits from improvements to the chassis and driveline, enabling it to reduce its consumption by up to a further 2%, while at the same time increasing the payload by up to 114 kg (251 lbs). It is also introducing Optivision, a predictive cruise control system with GPS.
Renault pursued three main tracks in the upgrade, in addition to basic engine efficiency improvements: improving the aerodynamics to reduce fuel consumption; reducing the weight to increase payload; and encouraging eco-driving by means of a predictive GPS navigation system, said Sophie Rivière, the Long Haul segment manager at Renault Trucks
New lineup of Intelligent Power Devices from Renesas contribute to reduced vehicle weight; high-current load switch applications
March 15, 2016
Renesas Electronics announced the availability of six new intelligent power devices (IPDs) for automotive motor and heater control applications. The devices provide an extremely reliable, high-performance solution compared with mechanical relays that switch the current flow on and off in electronic control units (ECUs).
An IPD is a power IC device that integrates in a single package control circuits that implement protection functions and self-diagnostic functions, in addition to power MOSFET (metal–oxide–semiconductor field-effect transistor) switching element(s). The IPDs are compact, lightweight, power efficient, and not subject to the contact wear and tear that affects mechanical relays, enabling highly reliable systems with self-protection functions.
Continental Structural Plastics and Mitsubishi Rayon exploring joint venture for carbon fiber automotive structural components
March 08, 2016
Continental Structural Plastics (CSP) has signed a memorandum of understanding with Mitsubishi Rayon (MRC), regarding the development and manufacturing of innovative carbon fiber structural components for the automotive industry in North America. Under the MoU, CSP and MRC will begin detailed studies to substantiate the establishment of an equity-based joint venture.
Specifically, the new joint venture will produce compression molded components made from carbon fiber reinforced plastic materials, which could include carbon fiber sheet molded compound (SMC) and/or Pre-preg carbon fiber Compression Molding (PCM).These components will include Class A body panels, as well as non-class A structural automotive applications including: pillars; engine cradles or supports; radiator supports; frames and rails; bumper beams; underbody shields; door inners and intrusion beams.
Faurecia using flax-based composite in Urban Liftgate demonstrator
March 07, 2016
Faurecia’s recently introduced Urban Liftgate demonstrator is a showcase for several innovations designed to rethink the rear-end of vehicles. Among the innovations is the use of a new type of composite made of natural flax fibers instead of carbon.
Although the flax-based composite is not comparable mechanically to carbon fiber composites, said Laurent Gillard, Senior Engineering Manager, it has its own intersting properties and offers a lower-cost than carbon fiber and an environmentally friendly solution for lightweighting. The flax-fiber composite provides a weight savings of around 45% Gillard said—in the ballpark of the estimated 50% weight savings from carbon fiber.
Toyota and Yanmar to collaborate on marine development and products; Toyota Hybrid Hulls
March 05, 2016
Toyota Motor Corporation and Yanmar Co., Ltd. have reached a wide-ranging agreement to collaborate on technical development, production, and mutual parts use in the marine industry. A concept craft previewing the first product developed under this collaboration was on display at the Japan International Boat Show this week.
Toyota currently manufactures and sells aluminum-hulled pleasure crafts equipped with automotive engines. Yanmar is an industrial device manufacturer that has specialized in industrial diesel engines. The company also manufactures marine engines, as well as fiberglass-reinforced plastic (FRP) fishing boats and industrial vessels.
Toho Tenax develops integrated production system for CFRP; projects in automotive
March 02, 2016
Toho Tenax Europe GmbH (TTE), the German subsidiary of Toho Tenax, itself the core company of the Teijin Group’s carbon fibers and composites business, has developed an integrated production system for carbon fiber-reinforced plastic (CFRP) that enables manufactured composite parts to be optimized for required shapes and properties.
The new production system uses a high-pressure resin transfer molding (HP-RTM) process and TTE’s own one-step carbon fiber to part technology, called Part via Preform (PvP), which it developed in 2014. One European automaker has already adopted this system and other projects are under way in the automotive industry.
DOE launches Energy Materials Network with $40M for first year
February 25, 2016
The US Department of Energy launched the Energy Materials Network (EMN), a new National Laboratory-led initiative. Leveraging $40 million in federal funding in its first year, EMN will focus on tackling one of the major barriers to widespread commercialization of clean energy technologies: the design, testing, and production of advanced materials. By strengthening and facilitating industry access to the unique scientific and technical advanced materials innovation resources available at DOE’s National Labs, the network will help bring these materials to market more quickly.
DOE’s Office of Energy Efficiency and Renewable Energy is providing the funding to establish EMN’s four initial National Laboratory-led consortia and solicit proposals for collaborative R&D projects with industry and academia. Each EMN consortium will bring together National Labs, industry, and academia to focus on specific classes of materials aligned with industry’s most pressing challenges related to materials for clean energy technologies.
Faurecia wins JEC World 2016 Innovation Award for “one-shot” composite manufacturing process; mass production slated for 2018
Faurecia has won a JEC World 2016 Innovation Award for its “one-shot” manufacturing process for visible composite parts; the approach combines structure and aspect in a single part. The technology makes it possible to insert a pre-heated thermoplastic composite reinforcement into the injection mold and secure it in a stable position.
The efficient process was demonstrated on a plastic tailgate with a pre-impregnated (prepreg) glass fiber reinforcement and is particularly suited to tailgates, lower tailgates and semi‑structural parts. The main benefits of this process are improvements in weight, quality, cost and cycle times.
New SwRI consortium to target advances in gasoline and diesel engine aluminum cylinder head designs
February 09, 2016
Southwest Research Institute (SwRI) announced the formation of a new consortium in partnership with leading castings solutions provider Grainger & Worrall (G&W) to advance automotive cylinder head designs. The Aluminum Head Evaluation, Analysis, and Durability (AHEAD) consortium seeks to reduce the weight while improving the durability of aluminum cylinder heads—an increasingly important need as materials and components are pushed to their limits in modern engines.Initially, AHEAD will target advances for aluminum cylinder heads used in both gasoline and diesel engines, such as casting processes, structural design, measurement and prediction of residual stresses, and aluminum alloy materials that resist high-temperatures. More advanced projects could include new alloy development, cylinder head transient analysis, materials characterization, and others.
Toho Tenax develops energy-saving, high-productivity carbonizing process and surface treatment technologies for CFRP
January 18, 2016
Toho Tenax Co., Ltd., the core company of the Teijin Group’s carbon fibers and composites business, has developed innovative microwave carbonization and plasma surface treatment technologies to support the increased production and use of carbon fiber reinforced plastic (CFRP) in automobiles, high-speed railcars and aircraft.
Toho Tenax is now working to commercialize the technologies for mass production in the coming future, when CFRP is expected to be used on an increasingly large scale. For CFRP solutions broadly incorporating everything from raw materials to composite materials, the company has been placing a special emphasis on reducing production-use energy and CO2 emissions by 50% while improving productivity.
UCLA researchers develop exceptionally strong and lightweight new metal nanocomposite
December 24, 2015
A team led by researchers from the UCLA Henry Samueli School of Engineering and Applied Science has created a super-strong yet light structural metal nanocomposite with extremely high specific strength and modulus, or stiffness-to-weight ratio. The new metal is composed of magnesium infused with a dense and even dispersal of ceramic silicon carbide nanoparticles. It could be used to make lighter airplanes, spacecraft, and cars, helping to improve fuel efficiency, as well as in mobile electronics and biomedical devices.
To create the super-strong but lightweight metal, the team developed a new way to disperse and stabilize nanoparticles in molten metals. They also developed a scalable manufacturing method that could pave the way for more high-performance lightweight metals. A paper on their work is published today in Nature.
Lux: 48V microhybridization could prove to be cost-effective means of achieving 2025 CAFE targets
December 21, 2015
Lux Research has built a bottom-up model for automotive innovation for fuel economy improvements to analyze the cost-effectiveness of all the various pathways for meeting regulatory fuel consumption and emissions targets.
The roadmap to reducing fuel consumption and emissions from the automotive sector has many options—including lightweight materials, increasing electrification, autonomy, and alternative fuels—but picking the right mix of options is tricky.
Ford and Corning introduce lightweight Gorilla Glass hybrid windshield technology on Ford GT
December 17, 2015
Ford and Corning have developed Gorilla Glass hybrid windshield technology—a light-weighting innovation set to debut on the all-new Ford GT. The Gorilla Glass hybrid is thinner and about 30% lighter than traditional laminate glass, and will improve Ford GT handling by lowering the vehicle’s center of gravity and positively impact acceleration, fuel economy and braking performance. The Gorilla Glass hybrid window will be used on both the windshield and rear engine cover of Ford GT.
When tasked with developing lightweight and advanced material vehicle applications, the Ford team approached Corning, a recognized leader in materials science that introduced light and durable Gorilla Glass to the consumer electronics market in 2007. Interested in further exploring potential automotive applications, Ford engaged Corning to help research and develop a unique formulation for exterior vehicle glass.
GM applies Gen 3 advanced high-strength steel in new vehicle for China; 1,200 MPa Q&P steel
December 03, 2015
General Motors is applying third-generation advanced high-strength steel to the new Chevrolet LOVA RV from SAIC-GM, thereby reducing the weight of selected body components by approximately 20%. The recreational vehicle (RV) was launched on 19 November 2015.
The new steel offers a superior balance of strength and ductility as compared to the first generation of high-strength steels. The fuel economy of a vehicle is generally considered to increase by 6 to 8% for every 10% reduction in body weight.
EuroCarBody Award 2015 goes to the Carbon Core body of the new BMW 7 Series
November 12, 2015
The Carbon Core body structure of the new BMW 7 Series has been awarded the EuroCarBody Award 2015 at the 17th Global Car Body Benchmarking Conference. The body of the new BMW luxury sedans was given a rating of 41.87 out of 50 possible points—the best score ever to be obtained in this competition. The EuroCarBody Award has been announced at the annual conference of experts every year since 2002 and is regarded as a leading award for innovations in car body construction.
The Carbon Core used for the body structure is the central element of the BMW EfficientLightweight Technology that was applied particularly consistently in the development of the sixth generation of the BMW 7 Series. For the first time in a volume-production automobile, a composite of CFRP, aluminium and super high-strength steels was created which increases rigidity and stiffness in the passenger cell while at the same time significantly reducing the vehicle weight.