Chrysler Gathering Patterns for Car Cast Materials.


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Chrysler Gathering Patterns for Car Cast Materials Paul Bujalski Boss Cast Metals Designing DaimlerChrysler Enterprise Materials Determination Patterns for Car Cast Materials Drivers Lower aggregate vehicle cost Labor Venture Materials Meet new execution prerequisites
Transcripts
Slide 1

Chrysler Group Trends for Automotive Cast Materials Paul Bujalski Supervisor-Cast Metals Engineering DaimlerChrysler Corporation

Slide 2

Materials Selection Trends for Automotive Cast Materials Drivers Lower aggregate vehicle cost Manpower Investment Materials Meet new execution prerequisites 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, and so forth.) Chassis Assemblies Austempered Ductile Iron: Crankshafts Suspension Components Future ? Run of the mill 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, and so on.) Chassis Assemblies Austempered Ductile Iron: Crankshafts Suspension Components Future ? Slim 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, and so on.) 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 ? Snake 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 predominant material. Iron will diminish yet stay essential. Composites will increment for low volume applications. Aluminum will develop and ought to turn into the number 2 material. Magnesium will have high development rate, however stay beneath 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. Fashioned/Forging-Casting Process Combinations. Magnesium Castings in Powertrain and Chassis Applications. Particular 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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