Materials & lightweighting: strategies, applications, opportunities

Publisher Name :
Date: 01-Sep-2015
No. of pages: 336

Materials & lightweighting: strategies, applications, opportunities" explores technical and production features of a wide variety of new materials that carmakers are turning to in the effort to meet lightweighting goals. The report is a deep-dive that covers topics including technical, strategic and cost challenges in the application of materials such as high-tech steels, aluminum alloys, magnesium and titanium.

The report report answers technical questions, outlines the strategies for each OEM, and suggests opportunities for suppliers. It provides analytical comparisons of the use of materials from quality, manufacturing and cost perspectives, and includes 36 detailed company profiles.

Materials & lightweighting: strategies, applications, opportunities

Table of Contents

1. Introduction 12
Government policy initiatives 15
Weight based versus footprint based initiatives 20
Weight based 95 g/km target 22
Footprint based 95 g/km 23
2. Barriers to weight reduction 26
Product differentiation 26
Vehicle weight and safety 27
Improved vehicle dynamics and safety 30
Process development 31
Cost development 32
3. Sustainability considerations 33
Mass reduction and vehicle lifecycle CO2 emissions 33
Case study Audi TT MY 2014 - 2015 36
End-of-life vehicles consideration 37
4. Historic perspective 41
5. Weight reduction by sector 48
Platform and module considerations 48
Body structure 52
Powertrain 54
Chassis 56
Interior developments 61
6. Materials technology 62
Steels 62
Steel industry global outlook 62
Advanced steel developments 63
Advanced alloy steels 68
Complex Phase steels (CP) 68
Dual Phase Steels (DP) 69
Ferritic-Bainitic Steel (FB) 70
Hot formed steel (HF) 70
Martensitic steel (MS) 71
Post forming heat treatable steel (PFHT) 71
Transformation-Induced Plasticity Steel (TRIP) 72
Twinning Induced Plasticity Steel (TWIP) 72
Boron UHSS 75
Special process steels 76
Evolving AHSS types 76
Three-phase steel with nano-precipitation 77
Quenching and partitioning 78
Competition from other materials 78
7. Steel forming technology 79
Hydroforming 79
Tailored blanks 79
Hot stamping 80
Zinc-Magnesium coated hot dip galvanised steel 82
Stainless steels for car frames 82
8. Aluminium alloys 84
Aluminium alloy systems 88
Wrought Alloy Series 89
Casting Alloys 92
Growth opportunities for aluminium 94
Powertrain applications 97
Chassis applications 100
Recycling 114
9. Magnesium 117
Magnesium versus aluminium 122
Price volatility 123
Demand for magnesium 127
Magnesium advantages 128
Magnesium extraction 131
Alloy and process development 132
Magnesium sheet production and stamping 137
Forging 139
10. Titanium 142
Titanium aluminides 144
Turbochargers 145
Titanium engine applications 146
Exhaust Systems 148
Titanium chassis applications 149
Brake Systems 149
Springs, bolts and fasteners 149
Lowering the cost of titanium 150
Extraction 150
Fabrication 150
11. Composite and Plastic Materials 153
Carbon Fibre 153
Types by raw materials: 157
Carbon fibre cost reduction 158
Process development 163
Thermocomposite materials 166
Thermoset versus thermoplastic 166
Plastics 169
Sheet moulding compound (SMC) 171
12. Nano-scale materials 173
Honeycomb structures 178
13. Hybrid materials technology 179
14. Bio-Materials 182
Challenges in bio-material application 183
Current and future applications 184
Textiles 188
Woven and knitted fabrics 188
Joining technology 191
Welding 191
Laser welding 191
Magnetic pulse welding 193
Plasma arc welding 194
Deformation resistance welding 195
Ultrasonic aluminium welding 195
Friction stir welding 197
Laser-Assisted Friction Stir Welding 198
Adhesive bonding 198
Hybrid bonding 201
Riveting 202
Self-piercing rivets 202
15. Company Profiles
Aapico Hitech Public Co.
Aichi Steel
Alcoa
Aleris
Amag Austria Metall
Arcelor Mittal
Basf
Benteler
CIE Automotive
Constellium
Faurecia
Georg Fischer
Gestamp
Gibbs Die Casting
GKN
Gurit
IMG
Iochpe Maxion
Kaiser Aluminium
Linamar Corporation
Luxfer Group
Magna
Martinea International
Meridian
Montupet SA
Novelis
Plastic Omnium
Shiloh Industries
Stemcor
Superior Industries
Tata Steel
Teijin
Thyssenkrupp
Tower International
Voestalpine
Yorozu Corporation
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