Advanced lightweight materials and manufacturing processes for automotive applications

Abstract

The global automotive industry is facing challenges in several key areas, including energy, emissions, safety, and affordability. Lightweighting is one of the key strategies used to address these challenges. Maximizing the weight reduction (i.e., minimizing vehicle weight) requires a systems-engineering design optimization and iteration process that combines material properties and manufacturing processes to meet product requirements at the lowest mass and/or cost. Advanced high-strength steels, aluminum and magnesium alloys, and carbon-fiber-reinforced polymers have emerged as important materials for automotive lightweighting. This article presents examples of how coupling materials science with innovative manufacturing processes can provide lightweight solutions in automotive engineering.