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overview


properties such as aluminum joined to steel or ceramics joined to steel are just a couple of examples—is an emerg- ing area of fundamental research that must mature to meet the needs of industry.


Improved Product Reliability and Performance Demands on product performance and reliability con- tinue to increase. For example, new cars and trucks on the showroom fl oor today are expected to have a reliable working life of 15 years or more and be able to achieve 200,000 miles. In contrast, it wasn’t too many years ago that a vehicle lifespan of seven or eight years and 100,000 miles was considered acceptable. Similar changes are occurring in the aircraft and power generation industries and other areas of manufacturing that involve high-cost, high-duty-cycle components. The challenge to achieve these stepwise improvements in reliability and product life is occurring at the same time there is a fundamental shift in the materials and manufacturing methods used to build many of these products and components. These challenges are likely to lead to radical advancements in joining and forming processes, methods for inspecting and assuring quality of manufactured products, computerized simulations to support design and prediction of performance as well as material processing methods.


Laser welding of automotive power train components replaces screw fasteners, reduces weight and provides other benefi ts.


and aerospace sectors, and even has growing emphasis in the offshore oil & gas industries. Lightweighting involves reducing the weight of engineered structures and compo- nents, most notably in the transportation industries, in an effort to reduce energy demands and provide environmental benefi ts. In some instances lightweighting also reduces the size or mass of structures (such as offshore oil platforms) and thus may reduce the cost of fabrication or increase payload and production capacities. A key technical driver to achieve lightweighting goals will involve the adoption of new and advanced metals, ceramics, composites and plastics, some of which have only recently become available on a large scale and which pose signifi cant challenges for joining and/or forming operations. The joining or forming of dissimi- lar materials—that is, materials having distinctly different


Reduced Product Cost Global competition forces manufacturers to constantly


fi nd ways to reduce the cost of designing and manufactur- ing products. Opportunities for technology advancement to meet this need are vast. Implementation of next-gen- eration automation tools, increased use of sophisticated modeling and simulation to accurately predict product performance and materials properties, more advanced in- process monitoring and quality control systems now gain- ing use throughout the manufacturing process to reduce scrap and rework requirements during production are but a few examples. These drivers apply across the manufac- turing spectrum from companies that have high-volume production demands to those that produce small numbers of specialized products such as aircraft manufacturers. In addition, product performance and reliability demands are forcing manufacturers to implement advanced materi- als, which may increase product cost in many circum-


20 — Motorized Vehicle Manufacturing 2015


Courtesy Trumpf


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