lightweight chassis initiatives gm’s global co2 f 2018 · engineer of body structures for tata...
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WORLDLightweighting
2018Integrated
MedIa PortfolIo
Unlocking the Right Combination
the move to mixed materials
The Aluminum Powder Metallurgy Option for Lightweighting
ULTrA-LighTweighT DriveLine PrOjecT
(COVER SHOT) REACH 25,000 AUTOMOTIVE LIGHTWEIGHTING PROFESSIONALS IN THE FIRST BIG ISSUE OF 2017!
JANUARY/FEBRUARY CONTENT HIGHLIGHTS
The Move to Mixed Materials: Unlocking the Right Combinations As manufacturers rise to meet government-mandated fuel economy and carbon dioxide targets, substituting lighter materials in place of steel is quickly becoming the most promising approach to weight reduction. With so many material options available, how do original equipment manufacturers and their supply chain partners determine the best route forward? In this article, John Johnston, Chief Engineer of Body Structures for Tata Technologies, sheds light on various mixed material approaches, including mixed intensive and lightweight intensive, which serve as jumping off points for many OEMs as they adjust their vehicle development strategies.
WHITE PAPER: REDUCING COMPONENT WEIGHT FOR AUTOMOTIVE APPLICATION A move to lighter weight products and components often begins with prototyping, where material and manufacturing process selection is paramount. But sorting through all the different possibilities is a huge challenge because improvements to product design in the automotive world isn’t a matter of grabbing whatever material weighs the least and replacing the legacy steel or iron used previously. This overview examines emerging trends and available options for engineers as they embark on the lightweighting path.
The Aluminum Powder Metallurgy Option for Lightweighting Newly developed materials based on aluminum PM technology are viable options for significantly more demanding applications for advanced power train technology and to achieve vehicle weight reduction in automobiles. The end result will be reduced CO2 emissions and fuel efficiency improvements.
WORLDLightweighting
T H E M AG A Z I N E O F I N N OVAT I O N + C O l l A b O R AT I O NJAN+FEb 2017 / lightweightingWorld.com
Ford’s Lightweight Chassis Initiatives
Q&A GM’s Global Co2 & Energy Center
director
OEM FOCUS
How-To
Aluminum Extrusion for
lightwEighting: Key Factors For success
rEDuCE Cost & wAstE whEn
Purchasing comPosites
WORLDLightweighting
T H E M AG A Z I N E o F I N N oVAT I o N + C o L L A b o r AT I o NJULY+AUGUsT 2017 / Lightweightingworld.com
»Plus Products + Processes, the latest news & MORe!
Unlocking the Right Combination
WORLDLightweighting
T H E M AG A Z I N E O F I N N OVAT I O N + C O l l A b O R AT I O N
MAR+APR 2017 / lightweightingWorld.com
HigH StrengtH SteelS expand
OeM OptiOnS
Chopped Fibers for tHerMOplaStiC
appS
InnovatIve MechanIcal JoInIng in-production plug-and-play Solutions
»plUS CalM’s Weight loss project — the latest news,Case stUDY & MORe!
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Inside+
WORLDLightweighting
T H E M AG A Z I N E O F I N N OVAT I O N + C O l l A b O r AT I O N
LightweightingWorld.com MAY+JUNE 2017
Innovative Advancements in Global Automotive Lightweighting Development
2017Corporate Capabilities
Updates on thermosets, pUlpress technology & a new generation of roller Bearings+
”“Lightweighting and the use of lightweight structural materials continues to lead the list of technologies to meet the 2025 CAFE standards.
/ 2017 Ward’s automotive trends survey /
Advanced Composites
Materials Poised for Growth
Aluminum
Steel
Fibers
Ceramics
Bio-Based Materials
Plastics
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lIgHtWeIgHtIngE V E R Y I S S U E . E V E R Y A R T I C L E . 3 6 5 D A Y S A Y E A R .Lightweighting World is the only trade publication in the automotive industry
exclusively dedicated to lightweighting design, engineering and manufacturing
processes. We target 25,000 decision makers with every issue. This combination
of targeted editorial and circulation gives you direct access to the designers,
engineers, and manufacturers who need your products to succeed. No other trade publication can match the power of our vertical reach to the industry.
100% InDUSTRY-DRIVEn EDIToRIAL ConTEnT
With technical and applications-driven content unmatched in the automotive
media, Lightweighting World engages readers with focuses on all the key areas
that relate to automotive lightweighting processes—including manufacturing
and engineering developments, new technologies, components, and materials.
Companies looking to profit in this burgeoning sector of the industry, make Lightweighting World their primary media partner because our team delivers results –that others simply can’t match.
The lightweight materials market value will grow to $133.1 billion by 2019 at aCAGR of 8.5%.
(Source: Markets and Markets)
In parallel with the expansion of the lightweight materials is the critical need for new designs, equipment and assembly solutions for all levels of the automotive supply chain.
$133.1 Billion
»IntroductIon
LightweightingWorld.com
Lightweighting worLd IS ThE InDUSTRY’S GATEwAY to the latest technical breakthroughs,
applications, trends and initiatives
for lightweight vehicle development.
We showcase how industry leaders are tackling the most pressing materials, design, manufacturing and production challenges. Each issue delivers peer-produced technical and applications content designed to help readers gain insight and collaborate for greater results.
Innovative people, companies and suppliers are helping to build momentum for vehicle weight reduction. Lightweighting World puts their contributions in the spotlight, as well as the initiatives that are key to success.
FEATURE COVERAGE
• Materials – including Steel, AHSS, Aluminum/Aluminum Alloys, Plastics/ Composites, Magnesium
• Design/Modeling/Simulation Tools
• Chemicals/Adhesives/Sealants
• Body Structures/Exterior Components
• Fastening/Joining/Bonding/Assembly Systems/Automation
• Vehicle Interiors & Components
• Engines & Components/Parts
• Drivetrains & Components
• Frame/Chassis Components
• Molding/Forming/Die-Cast Systems & Services
• Electrical Components
• Crash Safety Systems
• Testing/Analytical Instrumentation
• Tooling/Cutting Equipment/ Welding Services
• Furnace Systems for Materials Production
• Coatings/Surface Treatments
• 3D/Additive Products & Services
COLUMNS & DEPARTMENTS
• Starting Line – The latest news, trends and commentary
• Products+Processes – How specific solutions are being integrated into lightweighting initiatives
• Executive Insight – Enterprise level thinking on lightweighting initiatives
• Industry Focus – In-depth reports on the technologies and business moves impacting the vehicle lightweighting industry
• Lightweighting World Q & A’s – Industry experts share their insight with readers
» 22 Lightweighting worlD / JULY+AUGUST 2017
Lightweighting worlD / JULY+AUGUST 2017 23
lighter-weight components. In addi-tion to improved efficiency, efficient fundamentals also result in improved vehicle dynamics and drivability.
LW: In the automotive industry, lightweighting is a relatively new trend with competing priorities that impact it. From an organizational standpoint, what challenges do lightweighting initiatives bring to GM?
kLein: Lightweighting has become a cultural priority in engineering at General Motors. We have a saying, “Every engineer, every part, every gram matters.” Our engineers under-stand that every gram needs to earn its way into a vehicle. They all under-stand that their efforts are an impor-tant part of a larger system that, in the end, must deliver on the promise to our customers.
LW: While there is no silver bullet for lightweighting success, what is the most important aspect of lightweight vehicle manufacturing going forward? Increased use of mixed materials? Design and simulation of lightweight components? Tooling and production? All of the above?
kLein: A clearly defined vehicle mis-sion is the most important aspect of lightweighting. Having a clear under-standing of the goals and objectives of the vehicle, based on a clear under-standing of the customer, enables engineers to apply the best methods to reducing vehicle mass. With those
goals identified, engineers can correct-ly employ design and simulation tools to create an efficient topology and identify the right materials in the right gauges in the right locations to achieve the vehicle performance targets for ef-ficiency and safety. A mixture of steel types may make more sense for a high-volume and more mainstream vehicle like the Chevrolet Malibu. A more exotic combination of materials such as aluminum, carbon and steel may be better suited in a performance vehicle, like the Corvette.
LW: What is GM’s goal with its sus-tainability initiative? Meeting increas-ingly strict government fuel standards, emissions reduction, consumer demands and environmental considerations? All of the above?
kLein: We have a responsibility to our customers and our communities, and these are all important to us. General Motors has remained committed to improved fuel economy for our customers and a better environment for everyone. Nothing showcases our commitment more than our leadership in electric vehicles and the Chevrolet Bolt EV—the first EV for everyone
with 238 miles of range on a single charge and a net price of less than $30,000. The Bolt EV is a clear demon-stration of our commitment to innova-tion that builds jobs and customers for life. When it comes to General Motors’ environmental commitment, we’re focused on our products, our plants and our actions. Addressing climate change in an effective and sustainable manner requires a holistic approach involving all sectors of the economy.
LW: Granted, government regulations and emissions-reduction strategies of automotive manufacturers are a global trend. Here in the U.S., if the CAFE standards are reduced as a goal of the Trump administration, will GM continue to move forward with its vehicle lightweighting program at the same rate?
LightWeighting WorLd: How did lightweighting of GM auto-mobiles begin? Was it a top-down decision, or was it born in GM design and engineering labs? What drove that significant weight reduction in mass-production auto manufacturing, when many in the industry still view lightweighting as too expensive for big manufacturing numbers?
ChArLie kLein, gM: The drive for lightweight was born out of the drive for vehicle efficiency and with a keen focus on the customer. Our engineering leadership set the tone and expectation for excellence. GM engineering leadership built our strategy around what we call efficient fundamentals that are the backbone of vehicle programs. These efficient fundamentals include component optimization, advanced propulsion
technologies, aerodynamic refinement and focused lightweighting. While each individually contributes to the overall vehicle efficiency and driv-ability, they are more impactful when
combined and working synergistically. A lighter, more aerodynamic vehicle can be propelled by a smaller, more efficient engine than a heavier vehicle, for example. A lighter vehicle can use
Lightweighting World recently spoke with Charlie Klein, Executive Director, Global CO2 and Energy Center for General Motors. The automaker has made significant strides in its nearly fleetwide move to develop lighter vehicles, with several new models having an average weight reduction of 350 pounds per vehicle. We wanted to learn a lot more about the company’s impressive lightweighting initiatives and what’s driving them.
Q&A with Charlie Klein
Lightweighting has become a cultural priority in engineering at General Motors. We have a saying, “Every engineer, every part, every gram matters.”
INDUSTRY FOCUS
Cadillac uses a GM-patented aluminum spot-welding process
to join materials on the CT6. GM is the only manufacturer that can
now weld steel to steel, aluminum to aluminum and aluminum to steel
on the same manufacturing line.
26 Lightweighting worlD / JULY+AUGUST 2017
Lightweighting worlD / JULY+AUGUST 2017 27
FORD Lightweight Subframe Research & Development By David Wagner, Xiaoming Chen and John Uicker, Ford Motor Company /
Jonathan Weiler, Wanfeng Meridian / Andrew Swikowski and Nikhil Bolar,
Magna International
Engineering and technical leaders share the automaker’s R&D
efforts in lightweight chassis investigations, cast magnesium subframe
development and carbon fiber composite subframe design.
T he application of lightweight materials to reduce the
mass of a passenger vehicle provides a tangible fuel-
consumption reduction and an improved user experience.
Typically, a 10-percent reduction in vehicle mass, in
conjunction with engine downsizing, can provide a 6 to 8
percent fuel economy improvement. Additionally, mass
reduction can improve vehicle handling, which improves
the driving experience.
Alternative materials frequently challenge traditional
manufacturing and vehicle assembly operations. The use of
lightweight materials in bolt-on components, such as front
subframes, allows the challenges to be addressed at the
discrete bolted connections to the other vehicle compo-
nents and systems. Ford Motor Company, with its suppli-
ers, actively investigates lightweight materials to identify
opportunities to reduce vehicle mass. This will enhance fuel
economy and the customer’s user experience.
The typically higher material costs and global availabil-
ity of lightweight magnesium and carbon fiber composite
materials have limited high-volume commercialization of
these alternative material front subframes to the niche low-
volume premium vehicle segment and bolt-on components.
As customer demand for improved fuel economy and vari-
ous worldwide markets address CO2 and tailpipe emissions
regulations, the need for lightweight components grows year
over year. Both magnesium and carbon fiber composites
are attractive alternatives to steel and aluminum for light-
weight chassis components due to their low density and
high strength-to-mass ratios. Before the commercial issues
of these materials can be addressed, the design, manufactur-
ing and performance of front subframes of magnesium and
carbon fiber composite must be demonstrated.
Recently Ford Motor Company, with its suppliers,
conducted research and development projects investigat-
ing the opportunities and challenges associated with cast
magnesium and carbon fiber composite front subframes.
Wanfeng Meridian assisted with the development, then
produced prototype front crossmember subframes for
the Ford Focus. Magna Exteriors, the Magna Compos-
edItorIal overvIeW
LightweightingWorld.com
2018 edItorIal calendar
JulY / auguStAd Close: 06/14/2018
• Optimizing Multi-Material Approaches
• Materials: Aluminum
• Processes: Fastening/Joining/Assembly Solutions
• Products: Vehicle Interiors & Components
SePteMBer / octoBer Ad Close: 08/13/2018
• LIGHTWEIGHTING WORLD Conference 2018
• Processes: Tooling/Cutting Equipment/Welding
• Products: Furnace Systems for Materials Production
• Forming/Molding with Composites/Thermoplastics
noveMBer / deceMBer Ad Close: 10/15/2018
• Materials: Composites/Thermoplastics/Thermosets
• Processes: Heat Treated Castings for Lightweighting
• Products: Fastening/Joining Systems
• Lightweighting for Electric/Autonomous Vehicles
ConTEnT ThEMES & DEADLInES
JanuarY / feBruarYAd Close: 12/11/2017
• Q&A: Jaguar Land Rover, Chrysler
• Plastics Poised for Growth
• Design & Simulation Tools
• LIGHTWEIGHTING WORLD EXPO 2018 Call for Presentations
MarcH / aPrIl Ad Close: 02/12/2018
• Materials: High-Strength & Advanced Steels
• Processes: Molding/Forming/Die-Cast Systems
• Products: Chemicals/Adhesives/Sealants
• Lightweighting of Engine & Drivetrain Components
MaY / June Ad Close: 04/12/2018
• 2018 CORPORATE CAPABILITIES Special Section
• Processes: Integrating Composite Parts into Steel/ Aluminium Body
• Products: Frame/Chassis Components
• Crash Safety Systems
noTE All Ad Materials Due 3 Days After Ad Closing Dates. This editorial calendar features a general outline of key topics we will be addressing. Not every article and column planned for each issue is listed, and we welcome additional editorial ideas for any of our 2018 editions. The publisher reserves the right to make changes to this planning guide.
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Corporate Capabilities 2018Lightweighting World Magazine’s Corporate Capabilities is the first and only in-depth reference specifically designed for the automotive lightweighting industry. Whether you are a specialized niche manufacturer or global supplier, this is the one issue you can’t afford to miss.
From material choices, design and prototyping services to fabrication and manufacturing, new contracts and collaborations are happening now in the industry. Companies are positioning to be part of the action. Will your organization grow its share of this burgeoning market? Get a critical leg-up by participating in the Corporate Capabilities 2018 Edition from Lightweighting World.
To learn more, contact John Pellettieri v 818-368-5620 / m [email protected]
All full-page advertisers receive a full-page company profile directed across their ad. All half-page advertisers receive a half page profile surrounding their ad. ➔
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Corporate Capabilities 2018
Coming in the May/JUNE
edition of Lightweighting
World
KEY
PRODUCTS
+ SERVICES
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14 Lightweighting worlD / MAY+JUNE 2018
SSAB Americas
MAKE CONTACT
Dawn Shandler, Inside Sales Representativer
Phone: 248-864-2880
eMAIL: [email protected]
WeB: https://www.ssab.com/company/about-ssab/our-business/ssab-americas
ADDReSS: 4000 Town Center Suite 1450, Southfield, MI 48075 USA
Corporate
Capabilities 2018
THE AUTOMOTIVE STEEL
www.docol.com
As pioneers in advanced high-strength steel we’re a trusted partner
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Pittsburgh, PA - USA
P (419) 349-7661
Corporate Message
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WORLDLightweighting
T H E M AG A Z I N E O F I N N OVAT I O N + C O l l A b O r AT I O NLightweightingWorld.com
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Innovative Advancements in Global Automotive Lightweighting Development
2018Corporate Capabilities
Updates on thermosets, pUlpress technology & a new generation of roller Bearings
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