Advanced materials forlighter automotive structures

Nevio Di GiustoEUCAR Chairman

Advanced Materials International ForumBari, September 19th

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EUCAR overview

The automotive manufacturers founded EUCAR in 1994

as a platform and body to enable and support collaborative R&D in Europe

Today EUCAR representsthe 15 major European Automotive manufacturers

involved in Research & Innovation

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EUCAR Mission

Members collaborate in fields where there are common interests and non-competitive advantages, so as to:

Combine forces in a targeted way to devise strategies and solutions for future challenges

Develop and agree common frameworks that can serve as a basis for future standards

Gather the critical mass and necessary momentum for faster implementation of R&D results

To Strengthen the Competitivenessof the European Automotive

ManufacturersThrough Strategic Collaborative R&I

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SuperLightCar project

Weight reduction: 55kg (20%)Additional costs: < 2,5 €/kg

Highlights• Strut tower in austenitic

steel• Tunnel in hot-formed steel• Bodyside and B-pillar in

dualphase-steel• Roof in steel/polymer

compound• Fender in steel/polymer

compound

Motivation• Weight reduction with

increased utilization of high strength steels

Multi-material vehicle concepts lighter than 2004 benchmark

Multi material economic

Weight reduction: 74kg (27%)Additional costs: ~5 €/kg

Highlights• Longitudinal rail in

austenitic steel tailored welded blanks

• Suspension-strut mount as Al-diecast

• Tunnel in austenitic steel• Rear wheelhouse in Al-

diecast• Inner B-pillar in Al-diecast• Roof in Al-sheetMotivation• Multi-material design weight

reduction• Steel in the loading paths• Lightweight design

materials such as aluminum for the front end and roof

• Cast parts including high-integration

Weight reduction: 115kg (38%)Additional costs: ~10 €/kg

Highlights• Longitudinal rail in Trip800

tailored welded blanks• Strut tower as Mg-diecast• Floor panel in Al- and Mg-

blank• Wheelhouse and rear

longitudinal rail in Al-blank• Inner B-pillar in hot-formed

steel• Roof in Mg-sheetMotivation• Priority 1: Weight reduction• through multi-material

design• Priority 2: Number of parts• and cost targets

Steel intensiveMulti material advanced

Universal Light Body Concept

SuperLight Body Concept

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Evolution to lighter vehicles

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Advanced materials for Body

More than 70% of high strength

steels

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Weight 895 kg

Front axle weight 38%

Rear axle weight

62%

Alfa Romeo 4C

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► Light weight ► Structural efficiency

Alfa Romeo 4C - Carbon fiber monocoque

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REAR FRAMEFRONT FRAME

WEIGHT - 30%

- 20%INVEST.COST.

Functions: ► Crash management ► Engine support► Suspension support

Requirements: ► Weight ► Low investments► High modularity► High performance

Multi technologies: ► Extrusion process ► Stretch bending process► Die casting process ► CMT welding process

Alfa Romeo 4C – Frame solutions

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168 kg

NR. OF COMPONENTS (277) % IN WEIGHT

Alfa Romeo 4C - BIW weight

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NR. OF COMPONENTS (49)* % IN WEIGHT*

Alfa Romeo 4C - Hang on parts weight

39 kgw/o fenders

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NR. OF COMPONENTS (341)*% IN WEIGHT*

Alfa Romeo 4C – BIW

213 kgwith hang on parts

and fenders

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The challenge for advanced materials

MOREACCESSIBLE

PRICE

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Hivocomp project

Advanced materials enabling high-volume road transport applications of lightweight structural composite parts

ObjectivesCost reduction (material and process)Cycle time reductionConsistent quality at higher volumes Meet specific performance requirements for automotive and

other high-performance, high-volume applications:• increased toughness, even at low temperatures• drastically improved damage tolerance

Advanced polyurethane thermoset matrix materials offering:

• improved mechanical performance

• reduced cycle times in comparison with conventional matrix systems

Thermoplastic self-reinforced polymer composites incorporating continuous carbon fiber reinforcements (“hybridization”) offering:

• increased toughness

• reduced cycle times in comparison to current thermoplastic and thermoset solutions

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Hivocomp project

Demonstrators

Materials developed in the project have the potential:

• to produce lighter weight parts

• that are still cost and environmentally effective

Provided that:

• design is well optimized

• the carbon fiber cost and impacts continue to decrease over the coming years

Conclusions

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EFFICIENCY / CUSTOMIZATIONOF LIVING STRUCTURES

INTEGRATION AMONG DIFFERENT FIELDS OF KNOWLEDGE

Specialization Integration

From To

Leading edge research

System research

Improvement Breakthrough

Computer science

PhysicsMathematics

Mechanics

Electronics

Optics

BiologyPsychology

Sociology

New disciplines• Mechatronics• Micro & nano technologies• Infomobility• Infotelematics• E-drive• E-mobility• ………….

New competencies• Behavioral• Perceived• Environmental• Smart

• Safe• Haptic• Virtual• Reconfigurable• …………...

The target for innovation

Thanks for your attention