FY2006 Progress Report for Automotive Lightweighting Materials
The FY 2006 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
- Volume I (PDF 13.2 MB)
- Volume II (PDF 10.6 MB)
- Contents (PDF 114 KB)
- 1. Introduction (PDF 739 KB)
- 2. Automotive Metals
- 2a. Warm Forming of Aluminum II (PDF 300 KB)
- 2b. Active Flexible Binder Control System for Robust Stamping (PDF 914 KB)
- 2c. Die Face Engineering Project for Advanced Sheet Metal Forming (PDF 175 KB)
- 2d. Electromagnetic Forming of Aluminum Sheet (PDF 716 KB)
- 2e. Aluminum Automotive Closure Panel Corrosion Test Program (PDF 404 KB)
- 2f. Improved Automotive Suspension Components Cast with B206 Alloy (PDF 285 KB)
- 2g. Structural Cast Magnesium Development (PDF 1.2 MB)
- 2h. Magnesium Powertrain Cast Components (PDF 463 KB)
- 2i. Ultra-Large Castings of Aluminum and Magnesium (PDF 787 KB)
- 2j. High Integrity Magnesium Automotive Castings (HI-MAC) (PDF 259 KB)
- 2k. Magnesium Front End (PDF 510 KB)
- 2l. Magnesium Research and Technology Development (PDF 148 KB)
- 2m. Low-Cost Titanium Powder for Feedstock (PDF 654 KB)
- 2n. Low-Cost Powder Metallurgy Technology for Particle-Reinforced Titanium Automotive Components: Manufacturing Process Feasibility Study (PDF 151 KB)
- 2o. Powder-Metal Performance Modeling of Automotive Components (PDF 228 KB)
- 2p. High-Strength Steel Joining Technologies Project (PDF 585 KB)
- 2q. Hydroform Materials and Lubricants Project (PDF 342 KB)
- 2r. Sheet Steel Fatigue Characteristics Project (PDF 309 KB)
- 2s. Tribology (PDF 1.4 MB)
- 2t. High-Strength Steel Stamping Project (PDF 278 KB)
- 2u. Strain-Rate Characterization (PDF 288 KB)
- 2v. Modeling of High Strain-Rate Deformation of Steel Structures (PDF 710 KB)
- 2w. Lightweight Front End Structures (PDF 2.6 MB)
- 2x. Future Generation Passenger Compartment (PDF 176 KB)
- 2y. Lightweight Rear Chassis Structure (PDF 438 KB)
- 2z1. Characterization of Thermo-Mechanical Behaviors of Advanced High Strength Steels (AHSS): Part 1: Formability, Weldability and Performance Evaluations of AHSS Parts for Automotive Structures (PDF 446 KB)
- 2z2. Characterization of Thermo-Mechanical Behaviors of Advanced High Strength Steels (AHSS): Task 2 - Weldability and Performance Evaluations of AHSS Parts for Automotive Structures (PDF 862 KB)
- 3. Low-Cost Carbon Fiber
- 3a. Low-Cost Carbon Fiber from Renewable Resources (PDF 261 KB)
- 3b. Improved Lignin Purification/Recovery Process for Carbon-Fiber Applications (PDF 192 KB)
- 3c. Advanced Stabilization of PAN Fiber Precursors (PDF 1.0 MB)
- 3d. Advanced Oxidation of PAN Fiber Precursor (PDF 372 KB)
- 3e. Low-Cost Carbon-Fiber Manufacturing Using Microwave Energy (PDF 396 KB)
- 3f. Carbon-Fiber Systems Integration (PDF 344 KB)
- 4. Polymer Composites R&D
- 4a. Development of Manufacturing Methods for Fiber Preforms (PDF 325 KB)
- 4b. Development of Next-Generation Programmable Preforming Process (PDF 183 KB)
- 4c. High-Volume Processing of Composites (PDF 193 KB)
- 4d. Automotive Composites Consortium Focal Project 3 Composite-Intensive Body Structures (PDF 436 KB)
- 4e. Interphase Analysis and Control in Fiber-Reinforced Thermoplastic Composites (PDF 234 KB)
- 4f. Durability of Carbon-Fiber Composites (PDF 123 KB)
- 4g. Composite Crash-Energy Management (PDF 782 KB)
- 4h. Crash Analysis of Adhesively-Bonded Structures (CAABS) (PDF 484 KB)
- 4i. Engineering Property Prediction Tools for Tailored Polymer Composite Structures (PDF 546 KB)
- 4j. Simulation of Injection Molding of Thermoplastics Reinforced with Short and Long Fibers (PDF 166 KB)
- 4k. A Hierarchical, Structure-Oriented and Stochastic Approach to Model Liquid Molding Processes (PDF 221 KB)
- 4l. Simulation of Compression Resin-Transfer-Molding Process for Manufacturing Net-Shape Structures (PDF 517 KB)
- 4m. Incorporating Higher-Order Tensors in the Computation of Polymer Composite Mechanical Properties (PDF 300 KB)
- 4n. Linking Process-Induced Properties to Thermoplastic-Matrix Woven-Fabric Composites Performance (PDF 379 KB)
- 4o. Comparative Determinations of Orientation in Injection-Molded Thermotropic Liquid-Crystalline Copolyester (TLCP) Plaques (PDF 530 KB)
- 5. Joining
- 5a. Die-Cast Net-Shaped Hole Process Development for Application of Thread-Forming Fasteners (PDF 310 KB)
- 5b. Forming Limits of Weld Metal in Aluminum Alloys and Advanced High-Strength Steels (PDF 499 KB)
- 5c. Impact Modeling and Characterization of Spot Welds (PDF 252 KB)
- 5d. Friction-Stir Spot Welding of Advanced High-Strength Steel (PDF 918 KB)
- 5e. Long-Life Electrodes for Resistance Spot Welding of Aluminum Sheet Alloys and Coated High-Strength Steel Sheet (PDF 153 KB)
- 5f. Thermal-Drilling Application Development (PDF 159 KB)
- 6. Nondestructive Evaluation
- 6a. NDE Inspection of Resistance Spot Welds in Automotive Structures Using an Ultrasonic Phased Array (PDF 1.2 MB)
- 6b. Nondestructive Inspection of Adhesive Metal/Metal Bonds (PDF 286 KB)
- 7. Recycling
- 7a. Recycling Assessments and Planning (PDF 208 KB)
- 7b. Baseline Assessment of Recycling Systems and Technology (PDF 292 KB)
- 7c. Development of Technology for Removal of PCBs and Other Substances of Concern (SOCs) from Shredder Residue (PDF 288 KB)
- 7d. Compatibilization/Compounding Evaluation of Recovered Polymers (PDF 272 KB)
- 7e. Post-Shred Materials-Recovery Technology Development (PDF 321 KB)
- 8. Materials Crosscutting R&D
- 8a. Technical Cost Modeling (PDF 192 KB)
- 8b. Intermediate-Rate Crush Response of Crash Energy Management Structures (PDF 486 KB)
- Appendix A: Acronyms and Abbreviations (PDF 148 KB)