FY 2005 Progress Report for Automotive Lightweighting Materials

The FY 2005 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.

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Entire document in one file (PDF 22.0 MB)
Cover, Title Page, and Contents (PDF 295 KB)
1. Introduction (PDF 233 KB)
2. Automotive Metals
- 2a. Warm Forming of Aluminum II (PDF 419 KB)
- 2b. Active Flexible Binder Control System for Robust Stamping (PDF 731 KB)
- 2c. Die Face Engineering Project for Advanced Sheet Metal Forming (PDF 315 KB)
- 2d. Electromagnetic Forming of Aluminum Sheet (PDF 570 KB)
- 2e. Aluminum Automotive Closure Panel Corrosion Test Program (PDF 796 KB)
- 2f. Improved Automotive Suspension Components Cast with B206 Alloy (PDF 218 KB)
- 2g. Structural Cast Magnesium Development (PDF 966 KB)
- 2h. Magnesium Powertrain Cast Components (PDF 606 KB)
- 2i. Ultra-Large Castings of Aluminum and Magnesium (PDF 681 KB)
- 2j. Cost Assessment of Emerging Magnesium Sheet Production Methods (PDF 274 KB)
- 2k. Low-Cost Titanium Powder for Feedstock (PDF 482 KB)
- 2l. Ultra-Large Castings of Aluminum and Magnesium (PDF 306 KB)
- 2m. Powder Metal Performance Modeling of Automotive Components (PDF 1.0 MB)
- 2n. High-Strength Steel Joining Technologies Project (PDF 552 KB)
- 2o. Hydroform Materals and Lubricants Project (PDF 225 KB)
- 2p. Sheet Steel Fatigue Characteristics Project (PDF 208 KB)
- 2q. Tribology (PDF 138 KB)
- 2r. High-Strength Steel Stamping Project (PDF 314 KB)
- 2s. Strain-Rate Characterization (PDF 676 KB)
- 2t. Modeling of High Strain-Rate Deformation of Steel Structures (PDF 1.5 MB)
- 2u. Lightweight Front End Structures (PDF 1.9 MB)
- 2v. Future Generation Passenger Compartment (PDF 513 KB)
- 2w. Evaluations of the Effects of Manufacturing Processes and In-Service Temperature Variations on the Properties of TRIP Steels(PDF 518 KB)
3. Low-Cost Carbon Fiber
- 3a. Low-Cost Carbon Fiber from Renewable Resources (PDF 447 KB)
- 3b. Advanced Stabilization of PAN Fiber Precursors (PDF 145 KB)
- 3c. Advanced Oxidation of PAN Fiber Precursor (PDF 206 KB)
- 3d. Low-Cost Carbon-Fiber Manufacturing Using Microwave Energy (PDF 201 KB)
- 3e. Carbon-Fiber Systems Integration (PDF 171 KB)
4. Polymer Composites R&D
- 4a. Development of Manufacturing Methods for Fiber Preforms (PDF 685 KB)
- 4b. Development of Next-Generation Programmable Preforming Process (PDF 639 KB)
- 4c. High-Volume Processing of Composites (PDF 466 KB)
- 4d. Automotive Composites Consortium Focal Project 3 Composite-Intensive Body Structure (PDF 1.2 MB)
- 4e. Low-Cost Test Methods for Advanced Automotive Composite Materials: Creep Compression Fixture (PDF 618 KB)
- 4f. Interphase Analysis and Control in Fiber-Reinforced Thermoplastic Composites (PDF 831 KB)
- 4g. Performance Evaluation and Durability Prediction of Dissimilar Material Hybrid Joints (PDF 238 KB)
- 4h. Durability of Carbon-Fiber Composites (PDF 751 KB)
- 4i. Composite Crash Energy Management (PDF 1.3 MB)
- 4j. Crash Analysis of Adhesively-Bonded Structures (CAABS) (PDF 551 KB)
- 4k. Engineering Property Prediction Tools for Tailored Polymer Composite Structures (PDF 686 KB)
- 4l. Simulation of Injection Molding of Thermoplastics Reinforced with Short and Long Fibers (PDF 205 KB)
- 4m. A Hierarchical, Structure-Oriented and Stochastic Approach to Model Liquid Molding Processes Modeling and Simulation of Compression Resin Transfer Molding (PDF 545 KB)
- 4n. Modeling and Simulation of Compression Resin Transfer Molding (PDF 246 KB)
- 4o. Incorporating Higher-Order Tensors in the Computation of Polymer Composite Mechanical Properties (PDF 341 KB)
5. Joining
- 5a. Die-Cast Net-Shaped Hole Process Development for Application of Thread-Forming Fasteners (PDF 347 KB)
- 5b. Forming Limits of Weld Metal in Aluminum Alloys and Advanced High-Strength Steels (PDF 460 KB)
- 5c. Friction-Stir Spot-Welding of High-Strength Steels (PDF 316 KB)
- 5d. Long-Life Electrodes for Resistance Spot-Welding of Aluminum Sheet Alloys and Coated High-Strength Steel Sheet (PDF 331 KB)
6. Non-Destructive Evaluation
- 6a. NDE Tools for the Evaluation of Laser-Welded Metals (PDF 100 KB)
- 6b. NDE Inspection of Resistance Spot-Welds in Automotive Structures Using an Ultrasonic Phased Array (PDF 456 KB)
7. Recycling
- 7a. Recycling Assessments and Planning (PDF 236 KB)
- 7b. Baseline Assessment of Recycling Systems and Technology (PDF 1.1 MB)
- 7c. Development of Technology for Removal of PCBs and Other Substances of Concern (SOCs) from Shredder Residue (PDF 243 KB)
- 7d. Compatibilization/Compounding Evaluation of Recovered Polymers (PDF 278 KB)
- 7e. Post-Shred Materials Recovery Technology Development (PDF 798 KB)
8. Materials Crosscutting R&D
- 8a. Technical Cost Modeling (PDF 156 KB)
- 8b. Intermediate-Rate Crush Response of Crash Energy Management Structures (PDF 876 KB)
- 8c. Structural Reliability of Lightweight Glazing Alternatives (PDF 513 KB)
Appendix A: Acronyms and Abbreviations (PDF 128 KB)
Back Cover (PDF 205 KB)