Body

GM tools up for high-volume aluminum structures with new welding technology The process centers on a new electrode-tip design. It will enable GM’s global body shops to spot-weld virtually any combination of aluminum sheet, extrusions, and castings at higher production rates than are currently used in automotive aluminum-structures manufacturing. Read full story

Lightweight sandwich structures for EV chassis Plastic foam-core/aluminum-skin sandwich components developed by Inrekor in collaboration with JSP cut the weight of a prototype EV chassis by 30%. Read full story

Materials lead the way to vehicle mass reduction Reducing a vehicle's mass opens the door for a downsized engine and transmission, a lighter cradle and body structure, smaller wheels and brakes, as well as a weight-slimmed suspension. The start point for this ripple effect is materials. Read full story

Video: AHSS structures save lives, pose challenges to first responders Ron Moore, retired Division Chief of the McKinney (TX) Fire Department, has literally written the book on extrication involving vehicles with advanced high-strength steel structures, and he shared some of the challenges of this practice at the Great Designs in Steel seminar in Livonia, MI. Read full story

Galvanic corrosion modeling for aircraft environments Galvanic corrosion in aircraft is important as it occurs whenever dissimilar metals or certain types of composites are joined or are located close to each other. SICOM, a recent project involving Airbus, EADS, BEASY, and a number of research centers, investigated how the “find it and fix it” approach can be replaced by a more fundamental approach based on computer modeling. Read full story

Noise-damping lubricants control NVH, improve perceived vehicle quality Less noise and more smoothness are important design attributes for operators of most every type of vehicle, including passenger vehicles, heavy commercial vehicles, and off-road equipment. Synthetic noise-damping lubricants such as the Molykote brand solutions from Dow Corning can be economical, long-lasting answers to achieve these attributes in powertrain, body, chassis, and interior applications. Read full story

Developing steel cord reinforcement for injection molded parts BASF, Voestalpine, and Bekaert are working together to develop steel-cord-reinforced injection molded parts that the companies believe will make a significant contribution to vehicle safety. Read full story

Video Interview: SCM Metal focuses on lightweight future AEI spoke with SCM Metal Products’ Tom Pelletiers at the SAE 2012 World Congress about the North Carolina-based company’s next-generation lightweight materials. Read full story

JSP develops composite door-panel prototype A new concept for a 100% plastic prototype door panel has the potential to provide a weight reduction of up to 40% compared to conventional steel door panels but with equivalent performance (static strength), according to two JSP engineers who will present details of the prototype at the SAE 2012 World Congress in Detroit. Read full story