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In the automotive power train there is a lot of parts with very high but contradicting requirements: superior static and fatigue strength associated with low mass and particular inertia and vibration characteristics. In such cases it is very important to investigate residual strain / stress distribution as it influences to high extent the fatigue strength. For that purpose a test methodology consisting of semi-destructive, holographic interferometry, and non-destructive, 3D image correlation, measurements has been established. Small diameter blind hole drilling was used as the destructive method to relieve residual stresses dormant in the previously deformed material. Introduction of the void into balanced strain / stress fields in the relatively thin layer caused imbalance, residual stress gradient over the hole depth and therefore complex in- and out-of plane displacements. Those minute displacements were measured by means of holographic interferometry.

The desire for greater fuel efficiency and reduced emissions have accelerated a shift from traditional materials to design solutions that more closely match materials and their properties with key applications. The Multi-Material Lightweight Vehicle (MMLV) Project presents cutting edge engineering that meets future challenges in a concept vehicle with weight and life-cycle assessment savings. These results significantly contribute to achieving fuel reduction and to meeting future Corporate Average Fuel Economy (CAFÉ) regulations without compromising vehicle performance or occupant safety.