Fasteners & Sealing


4 The drive for more fuel efficient vehicles which retain a good level of performance has led to dramatic reductions in panel weight and a rethink of fastening techniques. Lawrence Large looks at some fabrication methods for lighter materials.


Vehicle design develops with environmental pressure


T


he growing need to protect the environment has led to a global drive to force down our dependence on fossil fuels and the emission they produce when consumed. The motor


industry in particular is seen as a sector where substantial gains can be made in the battle to reduce the carbon footprint. Making vehicles lighter gives a relatively quick, a lighter vehicle uses less fuel and better economy means that less carbon is emitted to the atmosphere. Environmentalists have agreed emission


reduction programmes which in many countries have led to legislation to reduce energy usage. In the US, for example, industry is now expected to cut emissions across the board to achieve the targets set out in the Copenhagen Accord which recognised the need to reduce global emissions back in 2009.


Reduced vehicle weights


Designers around the world are busy engineering lighter models by using stronger materials to reduce vehicle weights. Replacing steel panels with aluminium alloys or composites can substantially cut vehicle weights without jeopardising the vehicle’s strength and integrity. In the US, for example, Ford Motor Company is redesigning its most popular model, the F150 truck, utilising aluminium and magnesium instead of steel panels. The weight reduction achieved by this move, due


in 2014, is expected to produce sufficient reduction in carbon emissions to meet the company’s overall target. The 2012 C-Class shows how far Mercedes-


Benz has gone towards improving fuel efficiency of its entry-level saloon car. In European form, this year’s model is 31 per cent more fuel efficient than its predecessor thanks mainly to stop/start engine technology and weight reductions. Cars in the US will also get lighter panels, in particular a new aluminium bonnet, highlighting the company’s interest in weight reduction.


Fuel efficiency


Sustainability in vehicle design continues to be a driving force in the sector but to the car buyer who is searching for the best performing, yet most fuel-efficient vehicle, the areas where the greatest efficiency gains can be made may not always be that obvious. According to hardware specialist, Southco,


there is a continuing requirement in the design of new cars and trucks for the attachment of lightweight underbody protective shields. As well as contributing to weight reductions of the finished vehicle, these panels improve both aerodynamic efficiency beneath the vehicle and overall fuel economy by decreasing drag. More cars and more underbody protective shields are good news for companies within


Fig. 1. Ford Motor Company is redesigning its most popular model, the F150 truck, utilising aluminium and magnesium instead of steel panels.


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