![]() Automotive lightweighting with alternative materials By Don Rosato Share this article: Note: This is the second of a four-part series covering (1) automotive lightweighting trends, (2) material advances, (3) process technologies and (4) applications. Consumer preferences have limited the downsizing options available to automakers, and safety and performance standards have resulted in a very limited ability to reduce weight further with conventional materials. Every potential vehicle lightweighting component is under investigation. Material substitution replacing heavier iron and steel with weight-saving advanced composites and other plastics, aluminum, magnesium and advanced high-strength steel is essential for boosting vehicle fuel economy. Material substitution is dependent on mechanical properties, cost, design and manufacturing capabilities. In addition to reduced fuel consumption, weight reduction enables smaller power plant and energy storage systems, with corresponding cost and/or performance benefits as well as secondary weight reductions in load bearing structures. Plastic composites and other advanced plastics offer significant lightweighting potential. FRP (fiber reinforced plastics) composites are typically 25-35 percent lighter than steel parts of equal strength. Low- and ultra-low-density SMC (sheet molding compounds) advances are also facilitating weight reductions. New material uses to reduce weight will include:
Lightweighting measures are expected to be applied to every car model that is launched in the coming years. Mazda, for example, has set a goal to reduce the curb weight of all its new model cars by 15 percent (up to 220 pounds per car) through material replacement and engineering, redesigning features and shrinking part dimensions. The company is also looking to improve its global corporate fuel economy average by 30 percent by 2015. Innovative materials combined with new production methods and reinforcing structures will play an important role in reducing vehicle weight. This lower weight not only improves fuel efficiency but also reduces the load on the brakes and suspension systems. The average car contains 15 percent of its total weight, or 360 pounds, of plastics with use in automotive manufacturing accelerating. As the automotive industry gears up to meet new emissions regulations, lightweight plastics will play a critical role. Experts predict that these uses will more than double over the next five years.
Dr. Donald V. "Don" Rosato serves as president of PlastiSource, Inc. a prototype manufacturing, technology development and marketing advisory firm located in Concord, Massachusetts, USA, and is the author of the Vol 1 & 2 "Plastics Technology Handbook". |