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New Materials in the Automotive Industry Bernard Swiecki Center for Automotive Research (CAR) Blue Water Corridor Conference June 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 CAR Management Briefing Seminars CAR MBS: 49th year - August 4-7, Traverse City, Michigan 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 www.cargroup.org The New Big-3 Technology Shock ! Materials Connectivity Drive for fuel economy creating opportunities with evolving and new technologies Powertrain Harder Than It Seems - Achieved fuel economy and future standards 60 50 Passenger Car Standard CAFE (MPG) 40 Passenger Car Achieved 30 Light Truck Standard 20 Light Truck Achieved 10 0 1970 1980 1990 2000 2010 2020 2030 Lightweighting • 10% mass reduction = 7% better fuel consumption • Mass de-compounding effect (30%) Lightweighting: virtually limitless – but at what cost? 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 • • • • • • • 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.” Ford F-150 Lightweighting Material Architectural Strategy All technology pathways anticipate lightweighting Ford 2015 F-150 The “monolithic” car with one dominant material is: Aluminum body & bed – Easier to design, and Steel frame – 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. • Future Steel Vehicle – 35% reduction in body mass Source: Center for Automotive Research • Aluminum Intensive – 45% reduction in body mass • Composite Car - 55% reduction in body mass 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 You [email protected]