Achievements

In the materials area, the Partnership listed eight areas of major achievement in its presentations to the committee on January 26, 2012.32 These were as follows:

•  Completed design and manufacturability assessment of a magnesium front-end structure.

•  Completed design, tooling, fabrication, and testing of a one-piece composite underbody, saving 11.3 kg.

•  Optimized engineering and manufacturing processes for advanced high- strength steel (AHSS).

•  Developed a process for warm forming of aluminum and magnesium sheet.

•  Enhanced the formability of aluminum at room temperature.

•  Demonstrated a conversion technique for low-cost textile precursor for carbon fiber.

•  Improved performance of AHSS welds.

•  Developed a unique process for producing low-cost highly ductile magnesium sheet.

Response to Recommendations from the Phase 3 Review

Three recommendations on materials were made in the NRC Phase 3 report (NRC, 2010, pp. 108-109). The Partnership responses are shown below as “Updates.”

NRC Phase 3 Recommendation 3-22. The materials technical team should develop a systems-analysis methodology to determine the currently most cost-effective way for achieving a 50 percent weight reduction for hybrid and fuel cell vehicles. The materials team needs to evaluate how the cost penalty changes as a function of the percent weight reduction, assuming that the most effective mix of materials is used at each step in the weight-reduction process. The analysis should be updated on a regular basis as the cost structures change as a result of process research breakthroughs and commercial developments. [NRC, 2010, p. 108.]

Updates: DOE FY 2011 solicitation results for the multimaterial vehicle car (50 percent lighter than a midsized vehicle, design, build, and validate):

•  Award to Vehma (Magna International)—project started in November 2011.

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32 M. Zaluzec, Ford Motor Company, and C. Schutte, Department of Energy, “Materials Technical Team (MTT),” presentation to the committee, January 26, 2012, Washington, D.C.



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