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Chrysler Group Trends for Automotive Cast Materials Paul Bujalski Supervisor-Cast Metals Engineering DaimlerChrysler Corporation Materials Selection Trends for Automotive Cast Materials Drivers Lower total vehicle cost Manpower Investment Materials Meet new performance requirements

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Chrysler Group Trends for Automotive Cast Materials

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Chrysler Group Trends for Automotive Cast Materials

Paul Bujalski Supervisor-Cast Metals EngineeringDaimlerChrysler Corporation


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Materials Selection

Trends for Automotive Cast Materials

Drivers

Lower total vehicle cost

Manpower

Investment

Materials

Meet new performance requirements

Customer driven

Government driven


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Materials Data

Trends for Automotive Cast Materials

Density (g/cm3)


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Materials Data

Trends for Automotive Cast Materials

Cost


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Materials Data

Trends for Automotive Cast Materials

Material Properties


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Ranking for Structural Applications

Materials Data

Trends for Automotive Cast Materials

FRF =

(Tensile x Modulus)

(Cost x Density)


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Ferrous Applications

Current

Front Knuckle

Control Arms

Crankshafts

Camshafts

Engine Block

Con Rods

Thin-Wall Steel:

BIW Structures (B- Pillar, etc.)

Chassis Assemblies

Austempered Ductile Iron:

Crankshafts

Suspension Components

Future ?

Typical Ferrous Suspension

Castings


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Ferrous Applications

Current

Front Knuckle

Control Arms

Crankshafts

Camshafts

Engine Block

Con Rods

Thin-Wall Steel:

BIW Structures (B- Pillar, etc.)

Chassis Assemblies

Austempered Ductile Iron:

Crankshafts

Suspension Components

Future ?

Thin-Wall Cast Steel

Crossmember


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Aluminum Applications

Current

Front Knuckle

Rear Knuckle

Engine Cradle

Road Wheel

Engine Block

Cylinder Head

Transmission Case

Space Frames

(Cast Node/Extrusion Combination)

BIW Closure Panels

BIW Structures (B- Pillar, etc.)

Future ?

Pacifica / 300C / Magnum

Rear Suspension Links

Squeeze Casting Process

Saves Cost over Forging


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Magnesium Applications

Current

Steering Wheel

Instrument Panel

Steering Column Brkt.

Upper Mt. Brkt.

Pedal Sup. Brkt.

Future ?

Viper

Front of Dash Support

Transfer Case

Transmission Case

Liftgate, Cradles

Rear Seat Frame

Front Radiator Support

Oil Pan / Front Cover

Super Integrated Design Saves Weight and Cost


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Steel will remain the dominant material.

Iron will decrease but remain important.

Composites will increase for low volume applications.

Aluminum will grow and should become the number 2 material.

Magnesium will have high growth rate, but remain below 1-3% of the vehicle.

For the Future

Summary

Trends for Automotive Cast Materials


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Exterior Composites on the 2003 Dodge Viper

= SMC= RRIM


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Structural Composites on the 2003 Dodge Viper

= Glass Fiber SMC, LMC, GMT = Carbon Fiber SMC


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Thin-Wall Steel Castings-Integrating Weldments or Fabricated Assemblies into Single Component, BIW Structures.

Austempered Ductile Iron, More Machinable ADI Grades Targeting Chassis Applications.

Higher Strength Aluminum Alloys, 2xx/7xx Series. Wrought/Forging-Casting Process Combinations.

Magnesium Castings in Powertrain and Chassis Applications.

Specific Target Areas

Summary

Trends for Automotive Cast Materials


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Trends for Automotive Cast Materials

Thank You For Your Attention.

Any Questions?


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