Abstract
High Cost of Raw Materials
The lack of appropriate manufacturing process and the high cost of the raw
materials are some of the main reasons why lightweight materials like
composites are not widely used in mass production of automotive applications.
These materials have been mostly used in the low production volumes as it
involved lower investment costs.
Need for Fuel Efficiency and Reduction in Green House Gases
The easiest and the least expensive way to reduce the energy consumption and
emissions of a vehicle is to reduce the weight of the vehicle. To achieve
lightweight construction, without compensating on rigidity, automakers have
been investigating the replacement of steel with aluminium, magnesium,
composites, and foams. The recycling and recovery of end-of-life vehicles,
which involves recovery targets of 85%, are driving the auto industry to adopt
lightweight materials technology to meet these recovery targets.
Weight reduction is also the most cost-effective means to reduce fuel
consumption and greenhouse gases from the transportation sector. It has been
estimated that for every 10% of weight eliminated from a vehicle's total
weight, fuel economy improves by 7%. This also means that for every kilogram
of weight reduced in a vehicle, there is about 20 kg of carbon dioxide
reduction.
Automakers Working Towards Increased Use of Lightweight Materials
As there is a significant stress on greenhouse gas reductions and improving
fuel efficiency in the transportation sector, all automakers, suppliers,
assemblers, and component manufactures are investing heavily in lightweight
materials R&D and commercialization. All of them are working toward the goal
of increasing the use of lightweight materials and to gain more market
penetration by manufacturing components and vehicle structures made from
lightweight materials. Because the single greatest barrier to use of
lightweight materials is their high cost, priority is given to activities
aimed at reducing costs through development of new materials, forming
technologies, and manufacturing processes.
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