Review of the Research Program of the Partnership for a New Generation of Vehicles Second Report (1996) / Chapter Skim
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5 Structural Materials
5 Structural Materials
Pages 38-45
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From page 38... ...
Thermal efficiencies of approximately 40 percent are associated with more mature power sources, which are the most likely to meet the necessary performance requirements within the PNGV timeframe. At the other end of the scale, power sources with much higher efficiencies, such as fuel cells, may be less demanding in terms of needed vehicle-mass-reduction requirements but are relatively immature in their development and, hence, have a lower probability of meeting PNGV schedules.
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From page 39... ...
A series of workshops has been held with materials suppliers to identify materials research projects in response to the developments identified in the challenge tables. Workshop participants are encouraged to submit white papers outlining their proposed research.
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From page 40... ...
are underway to reduce the weight of steel-intensive vehicles by 20 percent or more through improved design techniques, advances in manufacturing technology, and wider use of high-strength steels. An analytical study by the Ultralight Steel Auto Body international consortium forecasts a weight of 205 kg (450 lb)
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From page 41... ...
While the forecast weight savings for aluminum usage are not controversial, the outstanding tasks listed by the PNGV suggest that more data are needed on the strength of aluminum weld bonds and crashworthiness of the aluminum intensive vehicles (Sherman, 19951. Weight reductions of up to 45 to 50 percent for body/chassis are considered attainable, based in part on supporting data from Ford's Aluminum Intensive Vehicle (AIV)
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From page 42... ...
For composites, manufacturing details, such as the method of fiber preform fabrication, fiber architecture, fiber angle, braid material properties, and molding processes, as well as the choice of fiber and resin systems, can be manipulated to alter substantially the in-service performance of a component. Thus, unlike most automotive structural metallic materials, for which the manufacturing processes generally provide simply a means for attaining a specific geometrical shape, the manufacturing process for composites is an essential determinant of both the properties and geometry of a finished part.
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From page 43... ...
ISSUES The PNGV has planned its next steps towards achieving the desired materials objectives as follows: Based on white papers developed following the supplier workshops, help initiate research projects with materials suppliers and other organizations aimed at meeting the challenges for aluminum and composite vehicles. Work with the AISI to develop structural concepts for steel vehicles and define materials challenges and research needs.
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From page 44... ...
The USCAR should continue to use the process it has developed incorporating its substantial leverage through integrated industry programs-to pursue the very promising developments in steel and aluminum materials made by materials suppliers and trade associations. The development of innovative manufacturing processes for aluminum and steel should be encouraged and accelerated.
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From page 45... ...
Presented to the Standing Committee to Review the Research Program of the PNGV at the National Academy of Sciences, Washington, D.C., October 30, 1995. PNGV (Partnership for a New Generation of Vehicles)
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