new materials in the automotive industry new materials in the automotive industry bernard swiecki...
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New Materials in the Automotive Industry
Bernard SwieckiCenter for Automotive Research (CAR)
Blue Water Corridor ConferenceJune 11, 2014
The Center for Automotive Research conducts leading-edge research that impacts the future of
the global automotive industry.
• Automotive industry contract research and service non-profit organization with more than 30 years experience
• CAR forecasts industry trends, advises on public policy, and sponsors multi-stakeholder communication forums
• Based in Ann Arbor, MI – 30+ Employees
Monday• Mapping the Pathway to World-Class Manufacturing• Connected and Automated Vehicles: Driving Forward Fast• Featherweight Competition: Agile, Light, and Strong
Tuesday• Advanced Powertrain Forum• Onwards and Upwards? The Sales Forecast Workshop• Attracting and Retaining Talent in an Era of Changing Technology
and Demographics• Managing the Global Supply Chain and Logistics: Moving all the
parts, on time, all the time
Wednesday• Automotive Strategy: Pathways to Prosperity• Designing for Technology and the Customer• Global Opportunities, Global Decisions, Final Outcomes
Thursday• Automotive Strategy: Pathways to Prosperity• Purchasing and Automaker/Supplier Relations in Today's
Automotive Industry
CAR MBS: 49th year - August 4-7, Traverse City, Michigan
CAR Management Briefing Seminars
www.cargroup.org
The New Big-3Technology Shock !
Materials Powertrain
Connectivity
Drive for fuel economy creating opportunities with evolving and new
technologies
Harder Than It Seems- Achieved fuel economy and future standards
1970 1980 1990 2000 2010 2020 20300
10
20
30
40
50
60
Passenger CarStandardPassenger CarAchievedLight TruckStandardLight TruckAchieved
CAFE
(MPG
)
Lightweighting
Lightweighting: virtually limitless – but at what cost?
• 10% mass reduction = 7% better fuel consumption
• Mass de-compounding effect (30%)
Ford F-150• One of Ford’s most profitable vehicles
• Best selling vehicle in the United States last year– Approximately 650,000 units sold per year– One vehicle every 50 seconds
• Best selling vehicle in 35 of 50 states according to Edmunds/Business Insider
Source: Business Insider
Ford F-150• High strength steel frame
– Increase from 23% to 77%• “Military grade” aluminum• 2.7 L Ecoboost engine w/start-stop• 700 lb. mass reduction
• Advanced steel and aluminum are the “primary pathways through 2020”
• Additional LW options with seats, IP, PT, etc.
• “There is barely a sufficient supply chain today for the Al on the F150.”
Source: Center for Automotive Research
LightweightingMaterial Architectural Strategy
• Future Steel Vehicle– 35% reduction in body mass
All technology pathways anticipate lightweighting
The “monolithic” car with one dominant material is:– Easier to design, and– Easier to manufacture, but– Not optimum for reducing mass and cost– Honda, “We’ve gone as far as we can with steel.” A MM body is next.
• Aluminum Intensive – 45% reduction in body mass
• Composite Car- 55% reduction in body mass
Ford 2015 F-150
Aluminum body & bedSteel frame
Key Material Trends (Next 10 years)
• Increased use of ultra high strength steel for structural components around the “safety cage” to prevent intrusion
• Aluminum use for chassis and exterior panels is increasing
• Fiber reinforced plastics (glass and carbon) for structural components are still several years away from high volume production
• Joining complexity: more laser welding, fasteners and adhesives
Structural Adhesive
Barriers to Lightweighting(Modeling, Joining, Supply Chain)
• Fitting into their traditional business model – change may take 2 generations
• Use of non-traditional materials and non-traditional suppliers• Performance (NVH, crash-simulation)• Cost • Assembly process• Time of construction• Required floor space• Bonding• Riveting• Corrosion• Global /standardized parts used in many models
New Bio-Based Material Study Underway at CAR- Make It In America Challenge
• Federally-funded grant program to accelerate job creation and encourage business investment in the United States– CAR’s portion is EDA-funded
• Project partners include:– National Center for Manufacturing Sciences (NCMS)– Michigan Manufacturing Technology Center (MMTC)– Macomb/St. Clair Workforce Development Board– Macomb County Community College
• 3 Year effort started in early 2014• Contact CAR to get involved
Thank [email protected]