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.
Table of Contents
1. Executive Summary
- 1. Introduction and Highlights of this Study
- 1. Introduction to this Study
- 2. Key Findings
- 2. Scope and Methodology
2. Technology and Materials Analysis
- 1. Technology Analysis
- 1. Engineering Issues
- 2. Application Trends
- 2. Material Analysis
- 1. Aluminum for Automotive Applications
- 2. Magnesium for Automotive Applications
- 3. Composites for Automotive Applications
- 4. Foams and Fibers for Automotive Applications
3. Innovative Developments in Automotive Applications of Plastics and Composites
- 1. Developments in North America
- 1. Rocky Mountain Institute's Hypercars
- 2. The Role of Specialty Thermoplastic Compounds in Automotives
- 2. Developments in Europe
- 1. Semicomposite Trailer by Euro-Projects
- 2. Cost-effective Injection Molding for Glass-Reinforced Composites
- 3. Continuous Production of TorHex Honeycomb Cores
- 4. FACT Gmbh's Long Fiber-Reinforced Thermoplastic Technology
- 5. Quadrant Plastic Composites
- 6. BI Plastics Paving the Way for Hybrid Thermoplastic Composites
- 3. Drivers and Challenges
4. Innovative Developments in Automotive Applications of Aluminum
- 1. Developments in North America
- 1. Synthesis of High-Strength Microstructures of Nickel-Aluminium Alloy
- 2. Aluminum Auto Parts Produced by Quick Forming Process
- 2. Developments in Europe
- 1. CANMET's Aluminum-Ceramic Brake Rotor Technology
- 2. The Art of Hydroforming Technology
- 3. Sulzer Metco's Thermal Spray Technology
- 3. Drivers and Challenges
5. Innovative Developments in Automotive Applications of Magnesium
- 1. Developments in North America
- 1. Thixomat's Thixomolding Technology
- 2. Meridian's Magnesium Engine Cradle
- 2. Developments in Europe
- 1. Keronite Magnesium Coatings
- 2. MAGNEXTRUSCO--Hydrostatic Extrusion of Magnesium
- 3. Drivers and Challenges
6. Innovative Developments in Automotive Applications of Foams and Fibers
- 1. Development in Foams
- 1. Aluminum Foams' Capability of Reducing Weight and Absorbing Energy
- 2. ROHACELL Hard Foams for Sandwich Structures
- 2. Development in Fibers
- 1. Hemp Fibers as Reinforcements for Composites
- 2. 3Tex's 3D Weaving Process
- 3. Drivers and Challenges for Fibers
- 4. Drivers and Challenges for Foams
7. Contact Details and Patents
- 1. Database of Key Industry Participants
- 1. Research Universities
- 2. Company
- 2. Patents Details
- 1. United States Patents
- 2. European Patents
8. Frost & Sullivan 2005 Science and Technology Awards
- 1. Technology Innovation Award
- 1. Award Description
- 2. Award Recipient
- 2. Product Innovation Award
- 1. Award Description
- 2. Award Recipient
- 3. Excellence in Technology Award
- 1. Award Description
- 2. Award Recipient
9. Critical Reference Tables
- 1. Decision Support Database Tables
- 1. Total Lightweight Vehicle Sales--World (1996-2004)
- 2. Lightweight Vehicle Sales--North America (2001-2011)
- 3. Light Commercial Vehicle (LCV) Sales--World (1996-2004)
- 4. Vehicle Scrap Rate--North America and Latin America (1996-2004)
- 5. Total Aluminum Consumption--World (1996-2004)
- 6. Aluminum Price per Tonne--World (1996-2004)
