Session 1 - Lightweighting
Chair: Dipl.-Ing. Alexander HoffmannHead of Technology - Development Metals- Audi AG, Neckarsulm, Germany
Session 1 consists of six presentations dealing with various aspects of lightweighting and weight reduction. The session presentations run from 15:00 until 18:00 o'clock.
15:00-15:30 Aluminium in innovative light-weight car design
Prof. Dr.-Ing. Jürgen HirschResearch & Development, Hydro Aluminium Deutschland GmbH, Bonn, Germany
Abstract
The state-of-the-art and latest developments of Aluminium in automotive applications are presented for European cars. The main Aluminium application can be found in power-train (engine, fuel system, liquid lines), chassis (cradle, axle) and car body (body-in-white, hoods, doors, wings, bumpers and interiors). With Aluminium weight saving of up to 50% can be achieved over competing materials in most applications without compromising safety, also in smaller cars suitable for cost efficient light-weight design in mass production. Advanced multi-material concepts are presented which better exploit the aluminium potential together with special steels, magnesium and plastics or composites, where applicable, i.e. the "best" material for the appropriate function is chosen. The results of the new “Super-Light-Car” SLC concept for a Golf V car is presented which reaches 34% weight reduction within a cost increment of 5 €/kg saved, using multi-material design and assembling technologies feasible for a high volume production ratio.
The state-of-the-art and latest developments of Aluminium in automotive applications are presented for European cars. The main Aluminium application can be found in power-train (engine, fuel system, liquid lines), chassis (cradle, axle) and car body (body-in-white, hoods, doors, wings, bumpers and interiors). With Aluminium weight saving of up to 50% can be achieved over competing materials in most applications without compromising safety, also in smaller cars suitable for cost efficient light-weight design in mass production. Advanced multi-material concepts are presented which better exploit the aluminium potential together with special steels, magnesium and plastics or composites, where applicable, i.e. the "best" material for the appropriate function is chosen. The results of the new “Super-Light-Car” SLC concept for a Golf V car is presented which reaches 34% weight reduction within a cost increment of 5 €/kg saved, using multi-material design and assembling technologies feasible for a high volume production ratio.
15:30-16:00 Analysis of Strength Relevance in Crash and Stiffness Relevance for typical Car Body Components
Dipl.-Ing. Sven FaßbenderInstitut für Kraftfahrzeuge Aachen (ika), Body Department, RWTH Aachen University, Germany
Abstract
The proposed paper will present the results of a study carried out by Institut für Kraftfahrzeuge RWTH Aachen University (ika) and the European Aluminium Association (EAA). The aim of that study was to quantify the stiffness and crash relevance of typical car body components systematically using numerical simulation. Based on that knowledge it is possible to determine which body components are potentially suitable for performance neutral weight reduction by creasing the material strength of the components. More specifically, on the one hands this enables to access the limit of further weight reduction possible using high strength steel. And on the other hand the stiffness and crash relevance of the components is used to evaluate the lightweight potential of aluminium in a multimaterial design approach. This includes determination of components most suitable for aluminium application.
The proposed paper will present the results of a study carried out by Institut für Kraftfahrzeuge RWTH Aachen University (ika) and the European Aluminium Association (EAA). The aim of that study was to quantify the stiffness and crash relevance of typical car body components systematically using numerical simulation. Based on that knowledge it is possible to determine which body components are potentially suitable for performance neutral weight reduction by creasing the material strength of the components. More specifically, on the one hands this enables to access the limit of further weight reduction possible using high strength steel. And on the other hand the stiffness and crash relevance of the components is used to evaluate the lightweight potential of aluminium in a multimaterial design approach. This includes determination of components most suitable for aluminium application.
16:00-16:30 Innovative forged and extruded components – a contribution to CO2 -reduction.
Dr.-Ing. Bernd VeltenHead of Technical Sales and Marketing, OTTO FUCHS KG, Meinerzhagen, Germany
Abstract
The increasing sensitivity for environmental requirements and the undoubted need for reduction of emissions, especially those of climate affecting so called greenhouse gases, put enormous pressure on the automotive industry to reduce fuel consumption and, hence, emissions. The current regulations of the European Union refer to these needs by formulating tough targets for the average C02-emission of the OEMs production programs, stating an upper limit for carbon emission from 2012. About 40 % of the overall consumption of a passenger car is caused by the mass. As a result the reduction of vehicle weight is an effective mean for consumption and emission reduction. The key characteristic for a successful development of lightweight components and introduction into series production is the relation between achievable weight reduction and additional production costs. The OTTO FUCHS KG as a world wide leading manufacturer of lightweight components from Aluminium, Magnesium and Titanium for aircraft and automotive application offers a wide range of technical solutions for extruded as well as forged components and high performance alloys. Some of the recent solutions for lightweight automotive forgings and extrusions will be presented.
The increasing sensitivity for environmental requirements and the undoubted need for reduction of emissions, especially those of climate affecting so called greenhouse gases, put enormous pressure on the automotive industry to reduce fuel consumption and, hence, emissions. The current regulations of the European Union refer to these needs by formulating tough targets for the average C02-emission of the OEMs production programs, stating an upper limit for carbon emission from 2012. About 40 % of the overall consumption of a passenger car is caused by the mass. As a result the reduction of vehicle weight is an effective mean for consumption and emission reduction. The key characteristic for a successful development of lightweight components and introduction into series production is the relation between achievable weight reduction and additional production costs. The OTTO FUCHS KG as a world wide leading manufacturer of lightweight components from Aluminium, Magnesium and Titanium for aircraft and automotive application offers a wide range of technical solutions for extruded as well as forged components and high performance alloys. Some of the recent solutions for lightweight automotive forgings and extrusions will be presented.
16:30-17:00 Weight Reduction with Aluminium Suspension, Chassis and Body Parts
Dr.-Ing. Heinrich FuchsHead of Materials and Process Development, HONSEL AG, Meschede, Germany
Abstract
17:00-17:30 New alloy possibilities for Automotive BIW
Jörg HeinTechnical Customer Service Automotive, Alcan Singen GmbH, Singen, Germany
Abstract
17:30-18:00 SeALUmax - High Performance Anodized Layers
Dr. sc. techn. Reiner SteinsHead of R&D, WKW Erbslöh Automotive GmbH, Wuppertal, Germany
Abstract
The paper deals with the technological response to increased corrosion resistance demands on decorative / functional anodized surfaces used on cars throughout the worldwide automotive industry. It gives a detailed look into the performance of what is considered a new era of anodizing quality and reveales structural improvements of the layers themselves. Finally, the customer is shown advantages, opportunities and cost efficient solutions.
The paper deals with the technological response to increased corrosion resistance demands on decorative / functional anodized surfaces used on cars throughout the worldwide automotive industry. It gives a detailed look into the performance of what is considered a new era of anodizing quality and reveales structural improvements of the layers themselves. Finally, the customer is shown advantages, opportunities and cost efficient solutions.