Lightweight solutions Multi-material constructions

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1 Lightweight solutions Multi-material constructions

2 Flanders DRIVE Index: Flanders DRIVE 1 Need for cost-efficient lightweight solutions 2 Multi-material constructions as a valuable solution 3 Our expertise 6 Advanced research and test facilities 14 Partner for innovation and development in the automotive industry Flanders DRIVE is a research institute for the vehicle industry situated near the Lommel Proving Ground in Belgium. Together with leading companies and research institutions, Flanders DRIVE works on high-tech, application-oriented research into the green and smart vehicle of the future. Flanders DRIVE supports the automotive industry through a wide range of activities, focusing on: Clean & Energy-Efficient Vehicles Lightweight Solutions Intelligent Driver & Traffic Systems Advanced Manufacturing Processes Intelligent Development Tools Flanders DRIVE is supported by the Flemish Government and offers its expertise to European projects 1

3 Need for cost-efficient lightweight solutions Overall vehicle weight increases due to e.g.: Multi-material construction as a valuable solution Using the right material at the right place creates opportunities to: Enhanced active and passive safety Integrate more functionalities Additional comfort features Optimise design (vision) Larger vehicle dimensions Reduce weight (today) Use of hybrid powertrains Lower costs Drivers and challenges for weight reduction -60% Goal 3 4 Drivers Challenges -40% Fuel economy Recycling quotas 5 6 Multi-material Raw material prices Safety design 1 Emission guidelines Steel Marketing strategy -20% 2 Steel (future) 2 Production costs 3 FRP 4 FRP (future) 1 5 Aluminium Cost reduction 2 6 Light metals (future) 3 Weight reduction

4 4 5

5 Our expertise Flanders DRIVE covers a wide range of competences: Requirements analysis Material selection Design for manufacturing Design optimisation Cost/performance optimisation Joining technology selection Adhesive bonding Simulation and testing Our approach to consistent and sustainable multi-material lightweight solutions: System functionalities & requirements analysis Derivation of component specifications System validation Component material & design optimisation Components Components integration and validation 6 joining technologies 7

6 Material selection: First selection, based on: expertise acquired in many research projects specialized information on materials in-depth knowledge about material suppliers benchmarking Final selection, based on physical testing and numerical simulation of top candidates All materials Definition of requirements Go / no go criteria Subset of possible materials Objectives to be reached Ranking Design optimisation: Create an optimal geometry, taking into account: manufacturing constraints and process parameters package space information and fixation points performance requirements realistic loads Applicable to castings, extrusions, welding structures, sheet metal, etc. Performance stiffness strength etc. Physical design limit Reduce mass How to leverage this potential? Increase performance 8 9 Top candidate Mass materials

7 Independent screening and selection of joining techniques: Identification of possible joining techniques Screening and selection based on lab tests and simulations Adhesives and structural tapes Adhesive joint Welding and soldering techniques Thermal joint Adhesive bonding: Product and production process requirements and analysis Joint design Adhesive system selection and optimisation Validation Production process adaptation and qualification Cost estimation Screwed joints, riveted joints Mechanical joint Hybrid joint Combination of joining techniques 10 11

8 Customised validation: Validation at component, system and vehicle level process customised to individual application (design verification plan) Testing and simulation of (in)correct use of systems in lab-created real-life conditions Physical testing Customised durability testing: Highly Accelerated Life Testing (HALT) combination of different types of loads (mechanical, thermal etc.) swift detection of weak points in a design Vibration testing based on road load measurements Functional testing Environmental (climate, UV, etc.) Strength & stiffness Accelerated/HALT durability VALIDATION Fatigue/life span prediction Multi-axial testing combining bending force and torque frequently occurring load situations standardized testing in realistic conditions Noise & vibration Dynamic analysis 12 Strength & stiffness analysis Stress analysis (linear/non-linear) 13 Virtual testing

9 Advanced research and test facilities Unique high-technology test rigs: Vehicle four-poster with climate chamber and sunlight simulation 4 individually controllable vertical hydraulic actuators 2 individually controllable horizontal hydraulic actuators pay loads up to 500kg per actuator General durability test rig High frequency vibration durability test rig up to 1000Hz force range +/- 5kN displacement range +/- 10mm random or sine-wave testing Full vehicle size climate chamber 10m x 6m x 6m temperature range: -40 C to +70 C, ΔT 0.3 C/min humidity range: 15 to 70% relative humidity sunlight simulation according to DIN up to 1100W/m² 600dm³ & 800dm³ climate chambers temperature range: -40 C to +180 C, ΔT up to 3.5 C/min humidity range: 15 to 98% relative humidity We also perform tests in cooperation with external laboratories 14 15

10 Contact information Flanders DRIVE Oude Diestersebaan Lommel Belgium tel fax

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