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