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 Youbswiecki@cargroup.org