FY 2004 Progress Report for Automotive Lightweighting Materials
The FY 2004 Progress Report for Automotive Lightweighting Materials focuses on the development and validation of advanced materials and manufacturing technologies, to significantly reduce automotive vehicle body and chassis weight without compromising other attributes such as safety, performance, recyclability, and cost.
The document is very large; it has been divided into sections for easier use. Each section is available as an Adobe Acrobat PDF. Download Adobe Reader
- Entire document in one file (PDF 16.35 MB)
- Cover, Title Page, and Contents (PDF 151 KB)
- 1. Introduction (PDF 233 KB)
- 2. Automotive Aluminum R&D
- 2a. Active Flexible Binder Control System for Robust Stamping (PDF 468 KB)
- 2b. Warm Forming of Aluminum II (PDF1.31 MB )
- 2c. Electromagnetic Forming of Aluminum Sheet (PDF 952 KB)
- 2d. Aluminum Automotive Closure Panel Corrosion Test Program (PDF 393 KB)
- 2e. Development of the Infrared Thermal Forming Process for Production of Aluminum Vehicle Components (PDF 250? KB)
- 3. Advanced Materials Development
- 3a. Low-Cost Powder Metallurgy Technology for Particle-Reinforced Titanium Automotive Components: Manufacturing Process Feasibility Study (PDF 398 KB)
- 3b. Low-Cost Cast Aluminum Metal Matrix Composites (PDF 330 KB)
- 3c. Structural Cast Magnesium Development (PDF 293 KB)
- 3d. Magnesium Powertrain Cast Components (PDF 216 KB)
- 3e. Low-Cost Titanium Evaluation (PDF 668 KB)
- 3f. Structural Reliability of Lightweight Glazing Alternatives (PDF 187 KB)
- 4. Polymer Composites R&D
- 4a. Development of Manufacturing Methods for Fiber Preforms (PDF 338 KB)
- 4b. Composite-Intensive Body Structure Development for Focal Project 3 (PDF 276 KB)
- 4c. High-Volume Processing of Composites (PDF 821 KB)
- 4d. Development of Next-Generation Programmable Preforming Process (PDF 385 KB)
- 5. Low-Cost Carbon Fiber
- 5a. Low-Cost Carbon Fibers from Renewable Resources (PDF 376 KB)
- 5b. Low-Cost Carbon Fiber Development Program (PDF 93 KB)
- 5c. Low-Cost Carbon Fiber Manufacturing Using Microwave Energy (PDF 148 KB)
- 5d. Oxidative Stabilization of PAN Fiber Precursor (PDF 227 KB)
- 6. Recycling
- 6a. Recycling Assessments and Planning (PDF 39 KB)
- 6b. Baseline Assessment of Recycling Systems and Technology (PDF 683 KB)
- 6c. Postshred Materials Recovery Technology Development and Demonstration (PDF 564 KB)
- 6d. Development of Technology for Removal of PCBs and Other Substances of Concern (SOCs) from Shredder Residue (PDF 39 KB)
- 6e. Compatibilization/Compounding Evaluation of Recovered Polymers (PDF 39 KB)
- 7. Enabling Technologies
- 7a. Durability of Carbon-Fiber Composites (PDF 359 KB)
- 7b. Interphase Analysis and Control in Fiber-Reinforced Thermoplastic Composites (PDF 314 KB)
- 7c. Low-Cost Test Methods for Advanced Automotive Composite Materials; Creep Compression Fixture (PDF 343 KB)
- 7d. Intermediate-Rate Crush Response of Crash Energy Management Structures (PDF 277 KB)
- 7e. Composite Crash Energy Management (PDF 320 KB)
- 7f. Crash Analysis of Adhesively Bonded Structures (CAABS) (PDF 394 KB)
- 7g. Long-Life Electrodes for Resistance Spot Welding of Aluminum Sheet Alloys and Coated High-Strength Steel Sheet (ORNL) (PDF 482 KB)
- 7h. Long-Life Electrodes for Resistance Spot Welding of Aluminum Sheet Alloys and Coated High-Strength Steel Sheet (USAMP) (PDF 257 KB)
- 7i. Plasma Arc Spot Welding of Lightweight Materials (PDF 26 KB)
- 7j. Performance Evaluation and Durability Prediction of Dissimilar Material Hybrid Joints (PDF 1.07 MB)
- 7k. Joining of Dissimilar Metals for Automotive Applications: From Process to Performance (PDF 197 KB)
- 7l. Application of Thread-Forming Fasteners (TFFs) in Net-Shaped Holes (PDF 103 KB)
- 7m. NDE Tools for the Evaluation of Laser-Welded Metals (PDF 421 KB)
- 7n. NDE Inspection of Resistance Spot Welds in Automotive Structures Using an Ultrasonic Phased Array (PDF 500 KB)
- 7o. Technical Cost Modeling (PDF 107 KB)
- 8. High-Strength Steels
- 8a. Evaluations of the Effects of Manufacturing Processes and In-Service Temperature Variations on the Properties of Transformation-Induced Plasticity (TRIP) Steels (PDF 35 KB)
- 8b. High-Strength Steel Stamping Project (PDF 91 KB)
- 8c. Strain Rate Characterization (PDF 1.04 MB)
- 8d. Development of Advanced Tools for Energy Management (PDF 336 KB)
- 8e. Lightweight Front Structures (PDF 408 KB)
- 8f. Hydroform Materials and Lubricants Project (CAABS) (PDF 150 KB)
- 8g. High-Strength Steel Joining Technologies Project (PDF 240 KB)
- 8h. Sheet Steel Fatigue Characteristics (PDF 73 KB)
- 8i. Tribology (PDF 218 KB)
- 8j. Lightweight Closure Panels Project (PDF 42 KB)
- Appendix A: Acronyms and Abbreviations (PDF 24 KB)
- Back Cover (PDF 89 KB)