Lightweight Materials for Automotive Applications

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.