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LIGHTWEIGHTING Lacks had concentrated on


fi nishes for automotive grilles and trim. “From 1998 to 2012, our product was used predominantly for how it looked,” Ardern said. “Then we started to realize in 2010, when we saw the light- weighting push, fundamentally our approach was very good for delivering lightweighting….If there hadn’t been this (fuel effi ciency) target out there, we could still be heavily focused on fi nishes.” Ardern said Lacks’ lighter wheel currently is on the Ram 1500 Big Horn truck. Rassini Frenos (Mexico City),


a producer of brake rotors, has been working with custom- ers on lightweighting issues. The company’s “fi rst wave” of lightweighting was to have a ductile aluminum brake hat, said Mauricio Gonzalez, engineering director for advanced brakes at Rassini’s Plymouth, MI, product development offi ce. The next phase, “that needs to happen around 2020,” in-


volves reducing the weight of the breaking surfaces with new composite materials that Rassini is trying to develop, he said.


What’s Coming NanoSteel (Providence, RI) designs alloys and licenses them to steel companies. NanoSteel-designed steels for automotive applications are currently being tested for metal fatigue and welding. “We’re very encouraged by the tests,” said Craig Parsons, president of automotive for NanoSteel. “People have talked about this high-strength and high-form- ability material for a long time.” It will still take years before such steel shows up in


production vehicles. In a follow-up e-mail, he said, “We are excited to work with the OEMs over the next several years to design the material into production vehicles.” LIFT is beginning to gain momentum. The manufacturing innovation institute is acquiring about $10 million in equip- ment to be used for lightweighting projects, Brown, the executive director, said. The electrical system of LIFT’s Detroit headquarters is being improved to ensure it can handle the load for the new equipment. “We’re talking about equipment to do pilot-scale devel- opment,” Brown said. Another one of the NNMI groups, the


A body in white for the multi-material Chrysler Pacifi ca minivan.


Institute for Advanced Composites Manufacturing Innovation (Knoxville, TN) has a satellite offi ce at LIFT. Both will work together on lightweighting-related projects. Industry groups for steel and aluminum say their members will be involved in lightweighting far beyond 2025. “I don’t think there’s going to be an end” to the light- weighting drive, said Jody Hall, vice president for automotive market of the Steel Market Development Institute. The industry faces “the never-ending quest for better,” said Doug Richman, chairman of the aluminum transporta- tion technology committee of the Aluminum Association. “The brilliant breakthrough fi ve years ago is now the industry norm and fi ve years from now will be obsolete.” Indeed, lightweighting increasingly is seen as a marathon, rather than a sprint to meet the 2025 model year standards.


“The technologies that get us to 2025 are different than the ones that get us to 2050,” CAR’s Jay Baron said. “It is clearly a marathon.”


?


Center for Automotive Research 734-662-1287 / cargroup.org


Lacks Enterprises Inc. 616-949-6570 / lacksenterprises.com


Lightweight Innovations for Tomorrow 313-309-9003 / lift.technology NanoSteel


877-293-6266 / nanosteelco.com


Rassini (Plymouth, MI offi ce) 734-454-4904 / rassini.com


September 2016 | AdvancedManufacturing.org 59


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