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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 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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Presentation Transcript
slide1

Chrysler Group Trends for Automotive Cast Materials

Paul Bujalski Supervisor-Cast Metals EngineeringDaimlerChrysler Corporation

drivers

Materials Selection

Trends for Automotive Cast Materials

Drivers

Lower total vehicle cost

Manpower

Investment

Materials

Meet new performance requirements

Customer driven

Government driven

density g cm3

Materials Data

Trends for Automotive Cast Materials

Density (g/cm3)

slide4

Materials Data

Trends for Automotive Cast Materials

Cost

material properties

Materials Data

Trends for Automotive Cast Materials

Material Properties

slide6

Ranking for Structural Applications

Materials Data

Trends for Automotive Cast Materials

FRF =

(Tensile x Modulus)

(Cost x Density)

slide7

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

slide8

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

slide9

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

slide10

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

slide11

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

slide13

Structural Composites on the 2003 Dodge Viper

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

slide14

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

slide15

Trends for Automotive Cast Materials

Thank You For Your Attention.

Any Questions?

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