Current Trends in Automotive Lightweighting Strategies and Materials

3D-Printed Carbon Scaffold for Structural Lithium Metal Batteries

Focus on advancement of energy storage has now turned to curbing carbon emissions in the transportation sector by adopting electric vehicles (EVs). Technological advancements in lithium-ion batteries (LIBs), valued for their lightweight and high capacity, are critical to making this switch a reality. Integrating structurally enhanced LIBs directly into vehicular design tackles two EV limitations: vehicle range and weight. In this study, 3D-carbon (3D-C) lattices, prepared with an inexpensive stereolithography-type 3D printer followed by carbonization, are proposed as scaffolds for Li metal anodes for structural LIBs. Mechanical stability tests revealed that the 3D-C lattice can withstand a maximum stress of 5.15 ± 0.15 MPa, which makes 3D-C lattices an ideal candidate for structural battery electrodes. Symmetric cell tests show the superior cycling stability of 3D-C scaffolds compared to conventional bare Cu foil current collectors. When 3D-C scaffolds are used, a small overpotential (≈0.075 V) is retained over 100 cycles at 1 mA cm-2 for 3 mAh cm-2, while the overpotential of a bare Cu symmetric cell is unstable and increased to 0.74 V at the 96th cycle. The precisely oriented internal pores of the 3D-C lattice confine lithium metal deposits within the 3D scaffold, effectively preventing short circuits.

Research Progresses on Technologies and Theory of Blanks with Variable Thicknesses

Under the background of dual carbon policy as well as energy conservation, blanks with variable thicknesses (BVTs) which act as structural components have drawn extensive attention due to their excellent strength and formability and reasonable load-bearing distribution characteristics, particularly in the field of automotive manufacturing. With these advantages, the manufacturing technologies of these plates using more efficient rolling methods have thus emerged. This article summarizes four methods and their characteristics for manufacturing plates with variable thicknesses based on rolling technology. In addition, a review is conducted on the latest research progress of the metal flow and rolling theories of existing plates with different thicknesses in the longitudinal and transverse direction.

Efficient Mako Shark-Inspired Aerodynamic Design for Concept Car Bodies in Underground Road Tunnel Conditions

The automotive industry continuously enhances vehicle design to meet the growing demand for more efficient vehicles. Computational design and numerical simulation are essential tools for developing concept cars with lower carbon emissions and reduced costs. Underground roads are proposed as an attractive alternative for reducing surface congestion, improving traffic flow, reducing travel times and minimizing noise pollution in urban areas, creating a quieter and more livable environment for residents. In this context, a concept car body design for underground tunnels was proposed, inspired by the mako shark shape due to its exceptional operational kinetic qualities. The proposed biomimetic-based method using computational fluid dynamics for engineering design includes an iterative process and car body optimization in terms of lift and drag performance. A mesh sensitivity and convergence analysis was performed in order to ensure the reliability of numerical results. The unique surface shape of the shark enabled remarkable aerodynamic performance for the concept car, achieving a drag coefficient value of 0.28. The addition of an aerodynamic diffuser improved downforce by reducing 58% of the lift coefficient to a final value of 0.02. Benchmark validation was carried out using reported results from sources available in the literature. The proposed biomimetic design process based on computational fluid modeling reduces the time and resources required to create new concept car models. This approach helps to achieve efficient automotive solutions with low aerodynamic drag for a low-carbon future.

Environmental Impact of Fused Filament Fabrication: What Is Known from Life Cycle Assessment?

This systematic review interrogates the literature to understand what is known about the environmental sustainability of fused filament fabrication, FFF (also known as fused deposition modeling, FDM), based on life cycle assessment (LCA) results. Since substantial energy demand is systematically addressed as one of the main reasons for ecological damage in FFF, mitigation strategies are often based on reducing the printing time (for example, adopting thicker layers) or the embodied energy per part (e.g., by nesting, which means by printing multiple parts in the same job). A key parameter is the infill degree, which can be adjusted to the application requirements while saving printing time/energy and feedstock material. The adoption of electricity from renewable resources is also expected to boost the sustainability of distributed manufacturing through FFF. Meanwhile, bio-based and recycled materials are being investigated as less impactful alternatives to conventional fossil fuel-based thermoplastic filaments.

Lightweighting in the automotive industry as a measure for energy efficiency: Review of the main materials and methods

The increasing emissions of greenhouse gases (GHG) and pollutants like particulate matter and nitrogen oxides (NOx) have led to environmental concerns. Hybrid and electric powertrains are being introduced as means to reduce pollutant emissions, especially at the local level. Additionally, the finite availability of fossil fuel sources, which are used to produce gasoline and diesel, highlights the need for alternative technical solutions. One approach to partly address these issues is lightweighting, which involves reducing the weight of vehicles to minimize their impact during the use phase. Mathematical models are employed to simulate the longitudinal dynamics of vehicles and estimate the energy required to accomplish driving missions. Appropriate metrics have been developed to quantify energy-saving effects that, in addition, can support the decision making, design, and development phase of future vehicles. To facilitate this process, it would be useful to build a database of ERV (Energy Reduction Value) and FRV (Fuel Reduction Value) figures derived through a unified procedure. Such a database would be useful in evaluating the effectiveness of vehicle lightweighting and its impact on energy consumption and pollutant emissions. The last phase of the analysis is the assessment of the overall reduction in the environmental impact of the vehicle throughout its life cycle by using the LCA (Life Cycle Assessment) approach. From this study, it was possible to conclude that lightweighting can be an appropriate solution to improve the energy efficiency of vehicles and that appropriate metrics, can support the development of new car models. The potential to integrate enhanced energy efficiency, lower emissions, and higher safety features into our everyday vehicles would represent a significant advancement in the automotive industry. There is a gap in the scientific literature on the effects of lightweighting on vehicle dynamics and energy usage which deserves to be investigated.

High-Performance Nanoscale Metallic Multilayer Composites: Techniques, Mechanical Properties and Applications

Due to their exceptional properties and diverse applications, including to magnetic devices, thermoelectric materials, catalysis, biomedicine, and energy storage, nanoscale metallic multilayer composites (NMMCs) have recently attracted great attention. The alternating layers of two or more metals that make up NMMCs are each just a few nanometers thick. The difficulties in producing and synthesizing new materials can be overcome by using nanoscale multilayer architectures. By adjusting the layer thickness, composition, and interface structure, the mechanical properties of these materials can be controlled. In addition, NMMCs exhibit unusually high strength at thin layer thicknesses because the multilayers have exceptionally high strength, as the individual layer thicknesses are reduced to the nanoscale. The properties of NMMCs depend on the individual layers. This means that the properties can be tuned by varying the layer thickness, composition, and interface structure. Therefore, this review article aims to provide a comprehensive overview of the mechanical properties and the application of high-performance NMMCs. The paper briefly discusses the fabrication methods used to produce these composites and highlights their potential in various fields, such as electronics, energy storage, aerospace, and biomedical engineering. Furthermore, the electrical conductivity, mechanical properties, and thermal stability of the above composite materials are analyzed in detail. The review concludes with a discussion of the future prospects and challenges associated with the development of NMMCs.

Effect of Temperature and Humidity Coupling on the Ageing Failure of Carbon Fiber Composite/Titanium Bonded Joints

Temperature and humidity coupling has a more significant effect on the failure properties of bonded joints than a single factor, and there is not enough research on this. In this paper, joints bonded with strong toughness structural adhesives are selected for the experimental analysis of joints aged for 240 h, 480 h, and 720 h at temperatures of 40 °C and 60 °C and a humidity of 95% and 100%. The sequential double Fick's model was used to fit the water absorption of the joints, and the comparison yielded that the water absorption of the adhesive was in accordance with Fick's law. The quasi-static tensile tests revealed that the reduction in mechanical properties of the joints was positively correlated with the moisture content in the environment, while the competing mechanisms of post-temperature curing and hydroplasticization resulted in a slight increase in the failure strength and energy uptake of the aged joints, which is in agreement with the experimental results of the Fourier infrared spectroscopy. A combination of macroscopic failure sections and scanning electron microscope (SEM) images yielded that the failure mode of the joints changed from cohesive failure to interfacial failure with increasing ageing time. In addition, reliability analyses for the fatigue testing of joints are expected to provide guidance for the life design of bonding technology in the vehicle service temperature range.

Vibration Fatigue Analysis of Two Different Variants of Oil Suction Pipes

In order to reduce the overall mass of the product, an improved variant of the engine oil suction pipe in hybrid design is developed and analysed as part of this paper. The vibration fatigue analysis of a simple all-metal suction pipe and the new hybrid suction pipe variant is derived using computer FEA simulations and vibration measurements on the shaker. The hybrid design of the technical components makes it possible to combine different types of materials in order to achieve the best possible properties and behaviours for the components under the influence of external loads. In our case, we combine a suction pipe made of S235JR mild steel with a 3D-printed polyamide intake funnel featuring a grid designed to prevent particles from entering the engine's lubrication circuit. This design reduces the mass and shifts the centre of gravity closer to the attachment point of the pipe, as well as to the engine crankcase, which has a positive effect on the values of natural frequencies and vibration amplitudes. The main objective of such a hybrid suction pipe is precisely to reduce vibrations, and thus extend the service life of the components.

Microstructural Characterization and Corrosion Behavior of Similar and Dissimilar Welded Advanced High-Strength Steels (AHSS) by Rotary Friction Welding

Advanced high-strength steels (AHSSs) are designed for meeting strict requirements, especially in the automotive industry, as a means to directly influence the reduction in the carbon footprint. As rotary friction welding (RFW) has many important advantages over other welding technologies, it plays an important role in the automotive sector. On the above basis, in this work, combinations of the first (complex phase (CP)), second (TWIP (TW)), and third (quenched and partitioned (Q&P)) generations of similar and dissimilar high-alloyed advanced steels have been joined by the RFW process. Having a specific microstructure, rods of CP/CP, Q&P/Q&P, CP/TW, and Q&P/TW steels were welded by employing a homemade adaptation machine under fixed parameters. Microstructural characterization has allowed us to corroborate the metallic bonding of all the tested advanced steels and to identify the different zones formed after welding. Results indicate that the welding zone widens in the center of the workpiece, and under the current friction action, the intermixing region shows the redistribution of solute elements, mostly in the dissimilarly welded steels. Furthermore, because of their complex chemistry and the different mechanical properties of the used steels, dissimilarly welded steels present the most noticeable differences in hardness. The TWIP steel has the lower hardness values, whilst the CP and Q&P steels have the higher ones. As a direct effect of the viscoplastic behavior of the steels established by the thermomechanical processing, interlayers and oxidation products were identified, as well as some typical RFW defects. The electrochemical response of the welded steels has shown that the compositional and microstructural condition mostly affect the corrosion trend. This means that the dissimilarly welded steels are more susceptible to corrosion, especially at the TWIP-steel interface, which is attributed to the energy that is stored in the distorted microstructure of each steel plate as a consequence of the thermomechanical processing during RFW.

Current Trends in Metallic Materials for Body Panels and Structural Members Used in the Automotive Industry

The development of lightweight and durable materials for car body panels and load-bearing elements in the automotive industry results from the constant desire to reduce fuel consumption without reducing vehicle performance. The investigations mainly concern the use of these alloys in the automotive industry, which is characterised by mass production series. Increasing the share of lightweight metals in the entire structure is part of the effort to reduce fuel consumption and carbon dioxide emissions into the atmosphere. Taking into account environmental sustainability aspects, metal sheets are easier to recycle than composite materials. At the same time, the last decade has seen an increase in work related to the plastic forming of sheets made of non-ferrous metal alloys. This article provides an up-to-date systematic overview of the basic applications of metallic materials in the automotive industry. The article focuses on the four largest groups of metallic materials: steels, aluminium alloys, titanium alloys, and magnesium alloys. The work draws attention to the limitations in the development of individual material groups and potential development trends of materials used for car body panels and other structural components.

Effect of Process Parameters on Joint Performance in Hot Pressure Welding of 6061 Aluminum Alloy to CF/PA66

Polymer-metal hybrid structures combine the merits of polymer and metal materials, making them widely applicable in fields such as aerospace and automotive industries. However, the main challenge lies in achieving efficient and strong connections between the metal and polymer components. This paper uses the jet electrochemical machining (Jet-ECM) method to customize the surface morphologies on 6061 aluminum alloy (AA6061) sheets. The connection between AA6061 and carbon fiber-reinforced PA66 (CF/PA66) is then achieved through hot pressure welding (HPW). The effects of aluminum alloy surface morphology, welding force, and welding time on the mechanical properties and microstructure of the joint are investigated. The optimal process parameters are determined by the design of the experiment. The results show that the aluminum alloy surface morphology has the greatest impact on the mechanical property of the welded joint. The optimal process parameters are surface morphology with wider, shallower, and sparsely distributed grooves on the aluminum alloy surface, the welding force is 720 N, the welding time is 12 s, the welding temperature is 360 °C, the cooling time is 16 s, and the optimal peak load of the joint is 6690 N. Under the optimal parameters, the fracture morphology in the AA6061 side is almost entirely covered with CF/PA66. The joint experiences cohesive failure in most areas and fiber-matrix debonding in a small area.

Recycling as a Key Enabler for Sustainable Additive Manufacturing of Polymer Composites: A Critical Perspective on Fused Filament Fabrication

Additive manufacturing (AM, aka 3D printing) is generally acknowledged as a "green" technology. However, its wider uptake in industry largely relies on the development of composite feedstock for imparting superior mechanical properties and bespoke functionality. Composite materials are especially needed in polymer AM, given the otherwise poor performance of most polymer parts in load-bearing applications. As a drawback, the shift from mono-material to composite feedstock may worsen the environmental footprint of polymer AM. This perspective aims to discuss this chasm between the advantage of embedding advanced functionality, and the disadvantage of causing harm to the environment. Fused filament fabrication (FFF, aka fused deposition modelling, FDM) is analysed here as a case study on account of its unparalleled popularity. FFF, which belongs to the material extrusion (MEX) family, is presently the most widespread polymer AM technique for industrial, educational, and recreational applications. On the one hand, the FFF of composite materials has already transitioned "from lab to fab" and finally to community, with far-reaching implications for its sustainability. On the other hand, feedstock materials for FFF are thermoplastic-based, and hence highly amenable to recycling. The literature shows that recycled thermoplastic materials such as poly(lactic acid) (PLA), acrylonitrile-butadiene-styrene (ABS), and polyethylene terephthalate (PET, or its glycol-modified form PETG) can be used for printing by FFF, and FFF printed objects can be recycled when they are at the end of life. Reinforcements/fillers can also be obtained from recycled materials, which may help valorise waste materials and by-products from a wide range of industries (for example, paper, food, furniture) and from agriculture. Increasing attention is being paid to the recovery of carbon fibres (for example, from aviation), and to the reuse of glass fibre-reinforced polymers (for example, from end-of-life wind turbines). Although technical challenges and economical constraints remain, the adoption of recycling strategies appears to be essential for limiting the environmental impact of composite feedstock in FFF by reducing the depletion of natural resources, cutting down the volume of waste materials, and mitigating the dependency on petrochemicals.

Durable Polyacrylic/Siloxane-Silica Coating for the Protection of Cast AlSi7Mg0.3 Alloy against Corrosion in Chloride Solution

This study presented a novel corrosion protective coating based on polyacrylic/siloxane-silica (PEHA-SS) deposited on lightweight cast aluminium alloy AlSi7Mg0.3. The synthesis of PEHA-SS comprises organic monomer 2-ethylhexyl acrylate and organically modified silane 3-(trimethoxysilyl)propyl methacrylate as well as an inorganic silane, tetraethyl orthosilicate. The steps during the synthesis process were monitored using real-time infrared spectroscopy. The coating deposited onto the AlSi7Mg0.3 surface was characterised using various techniques, including infrared spectroscopy, 3D contact profilometry, and scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy. The corrosion resistance of the coated alloy in sodium chloride solutions was evaluated using electrochemical impedance spectroscopy. The accelerated testing of the uncoated and coated sample was performed using the Machu test. This novel, nine micrometres thick PEHA-SS coating achieved durable corrosion (barrier) protection for the AlSi7Mg0.3 alloy in 0.1 M NaCl during the first four months of immersion or under accelerated corrosion conditions in a Machu chamber containing NaCl, acetic acid, and hydrogen peroxide at 37 °C.

Optimization of Machining Parameters to Minimize Cutting Forces and Surface Roughness in Micro-Milling of Mg13Sn Alloy

This comprehensive study investigates the micro-milling of a Mg13Sn alloy, a material of considerable interest in various high-precision applications, such as biomedical implants. The main objective of the study was to explore the optimizations of variable feed per tooth (fz), cutting speed (Vc), and depth of cut (ap) parameters on the key outcomes of the micro-milling process. A unique experimental setup was employed, employing a spindle capable of achieving up to 60,000 revolutions per minute. Additionally, the study leveraged linear slides backed by micro-step motors to facilitate precise axis movements, thereby maintaining a resolution accuracy of 0.1 μm. Cutting forces were accurately captured by a mini dynamometer and subsequently evaluated based on the peak to valley values for Fx (tangential force) and Fy (feed force). The study results revealed a clear and complex interplay between the varied cutting parameters and their subsequent impacts on the cutting forces and surface roughness. An increase in feed rate and depth of cut significantly increased the cutting forces. However, the cutting forces were found to decrease noticeably with the elevation of cutting speed. Intriguingly, the tangential force (Fx) was consistently higher than the feed force (Fy). Simultaneously, the study determined that the surface roughness, denoted by Sa values, increased in direct proportion to the feed rate. It was also found that the Sa surface roughness values decreased with the increase in cutting speed. This study recommends a parameter combination of fz = 5 µm/tooth feed rate, Vc = 62.8 m/min cutting speed, and ap = 400 µm depth of cut to maintain a Sa surface roughness value of less than 1 µm while ensuring an optimal material removal rate and machining time. The results derived from this study offer vital insights into the micro-milling of Mg13Sn alloys and contribute to the current body of knowledge on the topic.

Tensile Deformation and Fracture of Unreinforced AZ91 and Reinforced AZ91-C at Temperatures up to 300 °C

Magnesium alloys are still attractive materials for applications that necessitate light weight due to their low density, moderate strength, and good corrosion resistance. AZ91 is one of the widely applied magnesium alloys due to its very good castability and strength. However, one of the drawbacks of magnesium alloys is the low elastic modulus. So, reinforcing AZ91 with carbon short fibers with the aim of further increasing the strength and improving the elastic modulus is investigated in this study. Squeeze cast AZ91-23 vol.% carbon short carbon (AZ91-C) and the unreinforced AZ91 are deeply examined by tensile testing at different temperatures (20, 100, 150, 200, 250, and 300 °C). Tensile stress-strain curves are measured and the tensile parameters (yield stress, ultimate tensile strength and strain) are defined and presented against the test temperature. Yield stress of AZ91 at 20 °C (109 MPa) is doubled (226 MPa) in the reinforced AZ91-C. Yield stress is found to slightly decrease with increasing the test temperature. Ultimate tensile strength of AZ91 at 20 °C (198 MPa) is increased (262 MPa) in the reinforced AZ91-C. The improvement of the ultimate tensile strength due to reinforcing increases with increasing the test temperature. Flow curves are determined and described by a modified Mecking-Kocks relationship and the flow parameters are determined and described as a function of the test temperature. Microstructure investigation was undertaken of the fractured tensile specimens at the grain boundaries rich in eutectic structure formed at the grain boundaries. Mixed brittle/ductile fracture mode is detected on the fracture surface of unreinforced AZ91, while the SEM investigations show matrix/carbon fiber detachment and fiber fracture as main fracture modes.

Effect of Fiber Bundle Morphology on Fiber Dispersion for Long Fiber-Reinforced Thermoplastics

Understanding the mechanics of fiber attrition during the extrusion process is highly important in predicting the strength of long fiber-reinforced thermoplastic composites. However, little work has been done to investigate the mechanics of fiber dispersion and its effects on fiber attrition. This study aims at investigating fiber dispersion in simple shear flows for long fiber-reinforced thermoplastic pellets. Depending on the fabrication process, fiber bundles display distinct levels of compaction within the pellets. Studies have shown that morphological differences can lead to differences in dispersion mechanics; therefore, using a Couette rheometer and a sliding plate rheometer, coated and pultruded pellets were subjected to simple shear deformation, and the amount of dispersion was quantified. Additionally, a new image-based analysis method is presented in this study to measure fiber dispersion for a multi-pellet-filled system. Results from the single-pellet dispersion study showed a small amount of correlation between the dimensionless morphological parameter and the dispersion measurement. Pultruded and coated pellets were both found to have similar dispersion rates in a multi-pellet system. However, pultruded pellets were found to have a higher dispersion value at all levels when compared with coated pellets in both dispersion studies.

Application of Functionally Graded Shell Lattice as Infill in Additive Manufacturing

The significance of lightweight designs has become increasingly paramount due to the growing demand for sustainability. Consequently, this study aims to demonstrate the potential of utilising a functionally graded lattice as an infill structure in designing an additively manufactured bicycle crank arm to achieve construction lightness. The authors seek to determine whether functionally graded lattice structures can be effectively implemented and explore their potential real-world applications. Two aspects determine their realisations: the lack of adequate design and analysis methods and the limitations of existing additive manufacturing technology. To this end, the authors employed a relatively simple crank arm and design exploration methods for structural analysis. This approach facilitated the efficient identification of the optimal solution. A prototype was subsequently developed using fused filament fabrication for metals, enabling the production of a crank arm with the optimised infill. As a result, the authors developed a lightweight and manufacturable crank arm showing a new design and analysis method implementable in similar additively manufactured elements. The percentage increase of a stiffness-to-mass ratio of 109.6% was achieved compared to the initial design. The findings suggest that the functionally graded infill based on the lattice shell improves structural lightness and can be manufactured.

LCF and HCF of Short Carbon Fibers Reinforced AE42 Mg Alloy

Lightweight magnesium alloys and magnesium matrix composites have recently become more widespread for high-efficiency applications, including automobile, aerospace, defense, and electronic industries. Cast magnesium and magnesium matrix composites are applied in many highly moving and rotating parts, these parts can suffer from fatigue loading and are consequently subjected to fatigue failure. Reversed tensile-compression low-cycle fatigue (LCF) and high-cycle fatigue (HCF) of short fibers reinforced and unreinforced AE42 have been studied at temperatures of 20 °C, 150 °C, and 250 °C. To select suitable fatigue testing conditions, tensile tests have been carried out on AE42 and the composite material AE42-C at temperatures of up to 300 °C. The Wohler curves σ_a (N_F) have shown that the fatigue strength of the reinforced AE42-C in the HCF range was double that of unreinforced AE42. In the LCF range at certain strain amplitudes, the fatigue life of the composite materials is much less than that of the matrix alloys, this is due to the low ductility of this composite material. Furthermore, a slight temperature influence up to 150 °C has been established on the fatigue behavior of the AE42-C. The fatigue life curves Δε_total (N_F) were described using the Basquin and Manson-Coffin approaches. Fracture surface investigations showed a mixed mode of serration fatigue pattern on the matrix and carbon fibers fracturing and debonding from the matrix alloy.

An Approach to the Impact Simulation on Foamed Injection Molded Polypropylene Parts: An Example of Application in the Automotive Industry

An approach to the simulation of foamed injection molded Polypropylene parts subjected to impact loading is presented in this paper. The proposed method, which considers strain-rate-dependent material properties and the possible occurrence of fracture, is, in particular, suitable for parts manufactured with core-back technology. The method was developed to be used within the functionality of a commercial Finite Element solver using a shell-type element mesh. The material model is based on a three-layer structure, with two compact skin layers and a foamed core layer made of expanded material. The properties of the foamed material are assumed as those of the compact grade scaled by a suitable factor, which is identified via inverse engineering on a set of bending tests executed on specimens having different foam densities. The fracture of the material is then predicted using a damage model which considers the effects of triaxiality. The approach is then validated on industrial parts from the automotive sector, subjected to impact in a component test. Despite the simplicity of the presented approach, which makes this method suitable for industrial applications and especially for early-stage design, the validation shows a sufficiently accurate simulation of part behavior under the impact, with a reasonable prediction of damage and fracture.

Forging of an age-hardenable Mg–Al–Ca–Mn–Zn alloy on industrial scale

Weight reduction plays an important role in transportation industries, directly impacting on fuel consumption and vehicle range. The use of multi-material mixes is common practice, allowing for an optimum application of specific material properties. Light metals, primarily aluminum alloys, are used in both, cast and wrought state, to good effect. On the other hand, magnesium alloys, which are still lighter by one third, are used in castings exclusively. While scientific research and development on Mg wrought alloys is progressing steadily, industrial implementation is still scarce. As a result, safety relevant and structural applications made from Mg wrought products are nearly nonexistent. To increase acceptance and facilitate industrial application for this interesting class of materials we investigated the forging process of an original-sized automotive control arm. To ease industrial access, the used age hardenable Mg–Al–Ca–Zn–Mn lean alloy, can be processed similarly to Al alloys, e.g. 6xxx series. This work describes the development sequence, starting with the analysis of the forming window, followed by laboratory forging trials and industrial sized part production, providing information on forming characteristics as well as possible difficulties.

Thermal Plasma Synthesis of Different Alloys and Intermetallics from Ball Milled Al-Mo and Al-Ni Powder Systems

Lightweight alloys have great importance for car manufacturers that aim to produce safer, lighter, and more environmentally friendly vehicles. As a result, it is essential to develop new lightweight alloys, with superior properties to conventional ones, respecting the demands of the market. Al and its alloys are good candidates for reducing the overall weight of vehicles. The objective of this research was to understand the possibility to synthesize different Al alloys and intermetallics by implementing the plasma system and using two different Al-Ni and Al-Mo powder systems. This was done by separately injecting non-reacted raw Al-Ni and Al-Mo composite powder systems into the plasma reactor. In the first step, the milling parameters were optimized to generate Al-Ni and Al-Mo composite powders, with sizes over about 30 µm, having, respectively, a homogeneous mixture of elemental Al and Ni, and Al and Mo in their particles. Each of the composite powders was then injected separately into the plasma system to provide conditions for the reaction of their elements together. The obtained Al-Ni and Al-Mo powders were then studied using different methods such as scanning electron microscopy, X-ray diffractometry, and energy dispersive X-ray analysis. Regardless of the initially used powder system, the obtained powders were consisting of large spherical particles surrounded by a cloud of fine porous particles. Different phases such as Al, AlNi3, Al3Ni2, and AlNi were detected in the particles of the Al-Ni powder system and Al, Mo, AlMo3, MoO3, and MoO2 in the Al-Mo powder system.

Green Manufacturing-Oriented Polyetheretherketone Additive Manufacturing and Dry Milling Post-Processing Process Research

The application of polyetheretherketone (PEEK) in additive manufacturing (AM) can effectively reduce material and energy waste in the manufacturing process and help achieve lightweight parts. As a result, AM PEEK is considered an emerging technology in line with green manufacturing concepts. However, 3D-printed PEEK parts often suffer from low mechanical strength and poor surface quality due to the immaturity of the manufacturing process. Therefore, this research investigates the feasibility of improving the surface quality of 3D-printed parts by dry milling post-processing. Meanwhile, the mechanical strength of the parts is improved by optimizing the printing process parameters, and the effects of mechanical strength on milling quality are investigated. The novelty of this research is to design experiments based on the anisotropy of 3D-printed parts. For the first time, the delamination of the milling post-processing surface of 3D-printed PEEK parts is investigated. The results show that the milled surfaces of 3D-printed PEEK parts are prone to delamination problems. The printing direction has a significant effect on the quality of milling post-processing, whereas the milling directions have little effect on milling post-processing quality. The delamination problem can be significantly improved by a side milling process where the specimen is printed at 90° and then milled. Milling surface delamination is caused by the poor mechanical strength (internal bonding) of 3D-printed PEEK parts. By improving the mechanical strength of 3D-printed PEEK parts, the delamination of its milled surfaces can be significantly improved.

A Study on Hot Stamping Formability of Continuous Glass Fiber Reinforced Thermoplastic Composites

In this study, hot stamping tests on continuous glass fiber (GF)-reinforced thermoplastic (PP) composites were conducted under different process parameters using a self-designed hemispherical hot stamping die with a heating system. The effects of parameters such as preheating temperature, stamping depth, and stamping speed on the formability of the fabricated parts were analyzed using optical microscopy and scanning electron microscopy (SEM). The test results show that the suitable stamping depth should be less than 15 mm, the stamping speed should be less than 150 mm/min, and the preheating temperature should be about 200 °C. From the edge of the formed parts to their pole area, a thin-thick-thin characteristic in thickness was observed. Under the same preheating temperature, the influence of stamping depth on the thickness variation of the formed parts was more significant than the stamping speed. The primary defects of the formed parts were cracking, wrinkling, delamination, and fiber exposure. Resin poverty often occurred in the defect area of the formed parts and increased with stamping depth and stamping speed.

A Statistical Porosity Characterization Approach of Carbon-Fiber-Reinforced Polymer Material Using Optical Microscopy and Neural Network

The intensified pursuit for lightweight solutions in the commercial vehicle industry increases the demand for method development of more advanced lightweight materials such as Carbon-Fiber-Reinforced Composites (CFRP). The behavior of these anisotropic materials is challenging to understand and manufacturing defects could dramatically change the mechanical properties. Voids are one of the most common manufacturing defects; they can affect mechanical properties and work as initiation sites for damage. It is essential to know the micromechanical composition of the material to understand the material behavior. Void characterization is commonly conducted using optical microscopy, which is a reliable technique. In the current study, an approach based on optical microscopy, statistically characterizing a CFRP laminate with regard to porosity, is proposed. A neural network is implemented to efficiently segment micrographs and label the constituents: void, matrix, and fiber. A neural network minimizes the manual labor automating the process and shows great potential to be implemented in repetitive tasks in a design process to save time. The constituent fractions are determined and they show that constituent characterization can be performed with high accuracy for a very low number of training images. The extracted data are statistically analyzed. If significant differences are found, they can reveal and explain differences in the material behavior. The global and local void fraction show significant differences for the material used in this study and are good candidates to explain differences in material behavior.

Critical Minerals for Zero-Emission Transportation

Fundamentals of critical minerals and their paramount role in the successful deployment of clean energy technologies in future transportation are assessed along with current global efforts to satisfy the needs of automotive supply chains and environmental concerns. An implementation of large quantities of minerals, in particular metals, into the manufacturing of strategic components of zero-emission vehicles will bring new challenges to energy security. As a result, a reduced dependency on conventional hydrocarbon resources may lead to new and unexpected interdependencies, including dependencies on raw materials. It is concluded that to minimize the impact of a metal-intensive transition to clean transportation, in addition to overcoming challenges with minerals mining and processing, further progress in understanding the properties of critical materials will be required to better correlate them with intended applications, to identify potential substitutions and to optimize their use through the sustainable exploration of their resources and a circular economy.

A Novel Manufacturing Concept of LCP Fiber-Reinforced GPET-Based Sandwich Structures with an FDM 3D-Printed Core

The presented research was focused on the development of a new method of sandwich structure manufacturing involving FDM-printing (fused deposition modeling) techniques and compression molding. The presented concept allows for the preparation of thermoplastic-based composites with enhanced mechanical properties. The sample preparation process consists of 3D printing the sandwich's core structure using the FDM method. For comparison purposes, we used two types of GPET (copolymer of polyethylene terephthalate)-based filaments, pure resin, and carbon fiber (CF)-reinforced filaments. The outer reinforcing layer "skins" of the sandwich structure were prepared from the compression molded prepregs made from the LCP (liquid-crystal polymer)-fiber fabric with the GPET-based matrix. The final product consisting of an FDM-printed core and LCP-based prepreg was prepared using the compression molding method. The prepared samples were subjected to detailed materials analyses, including thermal analyses (thermogravimetry-TGA, differencial scanning calorimetry-DSC, and dynamic thermal-mechanical analysis-DMTA) and mechanical tests (tensile, flexural, and impact). As indicated by the static test results, the modulus and strength of the prepared composites were slightly improved; however, the stiffness of the prepared materials was more related to the presence of the CF-reinforced filament than the presence of the composite prepreg. The main advantage of using the developed method is revealed during impact tests. Due to the presence of long LCP fibers, the prepared sandwich samples are characterized by very high impact resistance. The impact strength increased from 1.7 kJ/m² for pure GPET samples to 50.4 kJ/m² for sandwich composites. For GPET/CF samples, the increase is even greater. The advantages of the developed solution were illustrated during puncture tests in which none of the sandwich samples were pierced.

An Experimentally Based Micromechanical Framework Exploring Effects of Void Shape on Macromechanical Properties

A micromechanical simulation approach in a Multi-Scale Modeling (MSM) framework with the ability to consider manufacturing defects is proposed. The study includes a case study where the framework is implemented exploring a cross-ply laminate. The proposed framework highlights the importance of correct input regarding micromechanical geometry and void characteristics. A Representative Volume Element (RVE) model is developed utilizing true micromechanical geometry extracted from micrographs. Voids, based on statistical experimental data, are implemented in the RVE model, and the effects on the fiber distribution and effective macromechanical properties are evaluated. The RVE algorithm is robust and maintains a good surrounding fiber distribution around the implemented void. The local void fraction, void size, and void shape affect the effective micromechanical properties, and it is important to consider the phenomena of the effective mechanical properties with regard to the overall void fraction of an RVE and the actual laminate. The proposed framework has a good prediction of the macromechanical properties and shows great potential to be used in an industrial implementation. For an industrial implementation, weak spots and critical areas for a laminate on a macro-level are found through combining local RVEs.

Intermediate Model Design in the Progressive Stamping Process of a Truss Core Lightweight Panel

The truss core panel has been verified to be effective for structural weight reduction in former research studies. However, it is difficult to manufacture using the sheet metal pressing method because the forming height of the truss core panel is limited by the physical properties of the material. Although progressive stamping has been used to solve this problem, it is still difficult to practically use the truss core panel. In this study, the author proposed a manufacturing method and a hexagonal frustum intermediate structure to improve the forming quality of truss core panels using a progressive stamping method and verified its effectiveness through numerical analysis and prototype experiments. Compared to the conventional hemispherical intermediate model, the manufacturing process of the truss core panel using the proposed method was significantly improved.

Light Electric Vehicles for Muscle–Battery Electric Mobility in Circular Economy: A Comprehensive Study

Light electric vehicles (LEVs) facilitate a significant reduction in global warming potential (GWP) and other environmental impacts related to specific transport performance due to their lightweight construction. Low-voltage systems in the drive engine, an open vehicle design and online vehicle data processing allow LEVs to be repaired by independent workshops, thus enabling long vehicle use as well as conversion or retrofitting for periods of use beyond 20 years. LEVs are not yet very common in everyday life in Western Europe. In order to support the acceptance of muscle power-supported LEVs in the EU L7e registration class by users, the vehicle design and construction specifically address requirements in the areas of last-mile parcel delivery and other transport services, including passenger transport. Life cycle assessment was used to investigate two construction methods for LEVs, mixed construction and fibre composite construction, in terms of the production, service life phase and end of life. A vehicle configuration was developed which, in addition to resource-saving production and long-life operation, enables easy access for users and maintenance of the LEV for various purposes. The resource efficiency of light electric vehicles was proven with regard to the ecological aspects. The vehicle design shown here shows high potential for LEVs in the circular economy.