Materials Research Agenda for the Automobile and Aircraft Industries (1993) / Chapter Skim
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Materials Research Agenda for the Automotive Industry
Materials Research Agenda for the Automotive Industry
Pages 29-48
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From page 29... ...
The specific findings address advanced materials candidates and corresponding research needs for the major component subsystems of the vehicle. NEED FOR MATERIALS-SYSTEMS APPROACH Improved materials and materials processing can and must play a large role in generating productive and effective responses to the forces that will drive the automotive industry in the future.
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From page 30... ...
Thus, in conducting R&D on new materials and processes for automotive applications, a comprehensive "systems" view must be adopted so that, in this larger context, the demanding and often conflicting requirements of the full automobile system can be taken into account. Materials Life Cycle Another aspect of the materials-system approach is the consideration of the materials life cycle as shown in Figure 3-1.
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From page 31... ...
~atcnals }tescarc* Pagoda for the ~utomoa~c industry 31
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From page 32... ...
Materials-Systems Research Unfortunately, much of the materials research at industrial and university laboratories has been driven by the search for improved materials properties with minimal attention paid to this systems approach. If researchers at academic institutions are to have significant impact on materials usage in the commercial automotive and aircraft industries, a new paradigm for prioritizing and guiding the research efforts must be found that defines goals at both the basic and applied levels in terms of the long-term system drivers.
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From page 33... ...
Lightweight Materials for Body Structure If market-driven requirements or government fuel-economy regulations specify 40 mpg or higher in the future, it will be necessary to reduce the average vehicle weight of the U.S. fleet by 500 - 1000 pounds, assuming that a 10 percent weight reduction yields a 5 percent increase in fuel economy (EEB, 1992~.
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From page 34... ...
Component Savings 56 Cost Cast Applications Cast Iron (Base) 1.0 1.0 Base Cast Aluminum 1.8 - 2.2 1.0 50~0 Cast Magnesium 3.0 1.0 65—75 Bodv Structural Applications Mild Steel (Base)
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From page 35... ...
On a component basis, however, the relative cost ratios are reduced due to the weight savings afforded by the lightweight-material options and, in some cases, by lower tooling and assembly costs resulting from part integration.
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From page 36... ...
. As also indicated in Table 3-1, aluminum currently represents a substantial cost penalty over steel (two times)
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From page 37... ...
Reduced cost, part consolidation, styling considerations, and weight savings have all contributed to the steady growth of plastics. For the use of structural composites, such as FRP, in major body parts, it appears that the cost penalty (i.e., higher cost of using this material)
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From page 38... ...
It will also be necessary to take advantage of secondary weight reductions (i.e., additional weight savings in subsystems that depend on the total vehicle weight)
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From page 39... ...
Gas turbine engines probably will require the use of ceramic components to achieve the high inlet gas temperatures required for high efficiency and small package size. Despite many years of government funded R&D in the Advanced Gas Turbine project, the cost, benefit, and reliability relationships for the ceramic turbine are still unclear.
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From page 40... ...
Reduction in the mass of engine valves, valve springs, and valve-spring retainers can be used to reduce friction losses and improve fuel economy appreciably for a given level of engine performance. Weight reduction of the engine block itself is driving the use of thinner cast-iron walls and the introduction of more cast aluminum.
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From page 41... ...
. The issues that must be addressed include properties at elevated temperature, cost, and development of a viable manufacturing infrastructure.
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From page 42... ...
The displacement of asbestos by alternative materials has proven difficult. The development of a systems science for automotive brakes, including the mechanical and materials aspects, should prove to be beneficial to both automotive manufacturers and brake component suppliers.
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From page 43... ...
catalysts dispersed in ceramic monoliths, containing some rare earths (Ce) , constitute the primary technology capable of meeting current emission standards in the United States and Japan and future standards in Europe and other countries.
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From page 44... ...
However, more stringent emission standards and increased regulations for in-use compliance will require increased use of PGMs in catalysts. Also, the platinum/rhodium ratio found in ore is such that excess platinum must be mined to meet the required rhodium contents in current catalytic systems.
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From page 45... ...
The matrix approach used in the life cycle charts allows the reader to cross-correlate material, application, and research required in such areas as processing, property enhancement, joining, repair, and recycling.
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From page 46... ...
46 Materials Research Agenda for the Automotive and Aircraft Industnes _ ;~ ~ Cal All-'.
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From page 47... ...
Matenals Research Agenda for the Automotive Indusoy 47 ._ c~ z a)
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