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MOTORINDIA
l
April 2012
The average vehicle weight
has increased steadily since
1980. This is due to pro-
duction of larger vehicles
(SUVs). The average light
vehicle in 2008 contained
more than 2,000 pounds
of steel, most of it conven-
tional steel. High and medi-
um strength steel, however,
made up more than 10 per
cent of the vehicle. The use
of aluminum grew during
1995-2008, while that of
iron castings declined.
Focus on Detroit
By Jay Baron, President and CEO, Center for Automotive Research (CAR)*
Integration of mixed materials to
reduce vehicle weight
The vehicle industry will continue
to see more mixed materials (com-
posites, aluminum, magnesium,
high strength steel) – issues with
joining and corrosion. It is going to
be steel vehicle vs. aluminum inten-
sive vehicle, looking for one-third
mass reduction that is cost neutral
but doesn’t recognize any realistic
constraints in vehicle making.
In assessment of technologies for
improving light-duty vehicle fuel
economy, there are over 40 tech-
nologies involved. For the next 15
years, improvements in fuel econo-
my are not technology limited but
cost constrained.
The objective of the Coalition for
Automotive Lightweighting Materi-
als (CALM) is to support the cost-ef-
fective integration of mixed materi-
als to achieve significant reductions
in mass through the collaborative ef-
forts of the material sectors and auto
manufacturers.
Currently, OEMs are integrators
of mixed materials. There is mini-
mal independent, mixed material
development. Material sectors are
highly competitive, each conducting
significant research that advances its
own material. Challenges lie in de-
sign, joining, corrosion prevention,
fabrication and long-term reliability.