material trends
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Material TrendsTRANSCRIPT
Material trends intelligenceservice
This PDF was generated from QUBE on:11 April 2013
Material trends intelligence service
Welcome to just-auto's material trends intelligence service
This service is based on previous (PDF-based) editions of just-auto's coverage of this sector. As such, it considers the major
companies, developments in key geographic regions, a look at emerging markets and reviews the latest technical
developments. Where possible, we also include market share data and forecasts out for several years.
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Updated: 2 Jan 2013
What's newApril 9, 2013HenkelHenkel
Henkel says in response to requirements of higher temperature and vibrational energy automotive sensor applications, it has
developed a new portfolio of silicone-based electrically conductive adhesives (ECAs) to address harsh environmental
conditions. The supplier maintains the Loctite Ablestik ICP 4000 series of ECAs withstand operating temperatures as high as
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200C and deliver the flexibility required to cope with significant vibration.
April 4, 2013Constell ium’s aluminium crash management systemConstell ium’s aluminium crash management system
Mercedes-Benz is sourcing Constellium’s aluminium Crash Management System for its C-Class vehicle. The system features
crash boxes inserted in the front structure of the car for improved safety.
April 2, 2013Woodbridge GroupWoodbridge Group
In June 2012, Woodbridge Group announced the development of a flame retardant foam for a range of under hood
acoustical and thermal insulating applications. Its so-called WhisperTech V0 foams are used in the engine bay, specifically
bonnet (hood) liners as well as dash insulators.
April 2, 2013Sumitomo CorporationSumitomo Corporation
In December 2012, Indonesian state-owned steel company PT Krakatau Steel announced an agreement to build a new steel
plant i
April 2, 2013SolvaySolvay
Solvay is an international chemistry group.
April 2, 2013Minda CorporationMinda Corporation
India's Minda Corporation is in the process of expanding capacity at its existing automotive plastic manufacturing unit in its
home country and plans two more plants by 2017. It is also expanding overseas with acquisitions. “We are expanding the
Chaken, Pune plant for completion by June 2012. We have decided to set up two more units - in Chennai, Tamil Nadu, by
the end of 2013 and the second one at Sanand, Gujarat, by the end of 2014,” business development chief Sandeep Aggarwal
told just-auto.
April 2, 2013Magna International Inc.Magna International Inc.
Magna International’s Exterior and Interior Systems business develops and manufactures a variety of parts, including front
and rear end fascia systems, exterior trim, class A composite panels, top systems, engineered glass, under hood and under
body components, and structural components.
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April 2, 2013Kobe SteelKobe Steel
Kobe Steel Ltd is one of Japan's major steel makers as well as a major supplier of aluminium and copper products. Its other
business segments consist of wholesale power supply, machinery, construction machinery, real estate, and electronic
materials and other businesses.
April 2, 2013Key PlasticsKey Plastics
In February 2012, Key Plastics completed a deal under which it sold a portion of its European operations in a management
buy-out. Innovative Components Technologies GmbH (ICT) of Germany has since become the owner and operator of former
Key facilities in Wachtersbach, Lennestadt and Kierspe, Germany; Tachov, Czech Republic; and Borja, Spain.
April 2, 2013Gestamp AutomocionGestamp Automocion
Gestamp is active internationally in the supply of metal components, modules and systems for the automotive industry
sector and has as its core business the automotive supply division Gestamp Automoción.
Introduction
For some time, the automotive industry has been under pressure to change the way it designs and builds vehicles, due to
factors such as the increasing impact of passenger and pedestrian safety requirements and the competitive intensity caused
by globalisation and manufacturing in low cost economies. Furthermore, governmental pressure in Europe and North
America to reduce CO2 emissions has prompted vehiclemakers and their supply base to develop automotive technology to
meet those strict emission limits. Consequently, more vehicles are incorporating components aimed at mass reduction,
parts consolidation to reduce assembly costs and more efficient recycling. The vehiclemakers’ need to improve overall fuel
economy in vehicles has led to the trend toward minimising vehicle weight. The use of performance materials such as high-
strength steel and aluminium is on the rise and heavier traditional materials, such as steel and iron, are being replaced
whenever possible.
About this service
This sector service reviews and forecasts the main materials used in vehicle manufacture, namely:
Steel
Aluminium
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On company overview page ofQUBE:
Sector activity Interviews& analysis PresentationsCompany newsCompetitors
External links:
Company site
Status:Status: Public
TurnoverTurnoverFY 2012 sales: US$929.7m
Stock symbolStock symbol : ACW
Accuride Corporation
Plastics
Iron
Glass
In addition, it reviews the use of other materials such as organic, carbon fibre and magnesium.
Our forecasts cover each of the above materials as a percentage of total kerb weight of a medium-sized passenger car.
Companies
This section is not intended to include all material manufacturers. Instead, it draws attention to a growing list of companies
which have developed or advanced the use of materials used in vehicle manufacture.
3M
In October 2012, 3M and Ceradyne entered into a definitive agreement for 3M's acquisition of Ceradyne for US$35.00 per
share. The proposed transaction has an aggregate value of approximately US$860m. Ceradyne develops and manufactures
technical ceramics for applications in the automotive, oil and gas, solar, industrial, electronics and defence industries.
In November 2012, 3M received clearance from the Austrian Federal Competition Authority with respect to its previously
announced tender offer for all issued and outstanding shares of common stock of Ceradyne at a price of US$35 per share.
Accuride Corporation is one of the largest and most diversified manufacturers of
commercial vehicle components in North America. Its products include commercial
vehicle wheels, wheel-end components and assemblies, truck body and chassis parts,
seating assemblies and other commercial vehicle components. Accuride’s products
are marketed under its brand names, which include Accuride, Gunite, Imperial,
Bostrom, Fabco, Brillion and Highway Original. These products are organised into
five categories, as follows:
wheels;
wheel-end components and assemblies;
truck body and chassis parts;
seating assemblies;
other commercial vehicle components.
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These products are further marketed under the following brand names:
Accuride Wheels – steel and aluminium wheels;
Gunite – wheel-end components;
Brillion – iron castings and non-powered farm equipment;
Imperial – truck body and chassis components;
Bostrom – seating assemblies (sold in early 2011);
Fabco – steerable drive axles, gearboxes and other truck components.
More specifically, Accuride is a major supplier of truck body and chassis parts to heavy- and medium-duty truck
manufacturers. The company fabricates a line of truck body and chassis parts under the Imperial and Highway Original brand
names, including bumpers, battery and toolboxes, crown assemblies, fuel tanks, roofs, fenders, and cross-members.
In addition, the company provides a variety of value-added services, such as chrome plating and polishing, hood assembly,
and the kitting and assembly of exhaust systems.
Bumpers – Accuride manufactures a variety of steel bumpers, as well as polish and chrome these products with pre-plate
and decorative polishing to meet specific OEM requirements, for its aftermarket brand—Highway Original, and private label
aftermarket requirements.
Fuel tanks -- Accuride manufactures and assembles aluminium and steel fuel tanks, fuel tank ends and fuel tank straps, as
well as polish fuel tanks for OEM and for its new Highway Original aftermarket customers.
Battery boxes and toolboxes – the company designs and manufactures, as well as polishes, steel and aluminium battery and
toolboxes for its heavy-duty truck OEM customers and Highway Original aftermarket brand.
Front-end cross-members – Accuride fabricates and assembles front-end crossmembers for heavy-duty trucks. A cross-
member is a structural component of a chassis. These products are manufactured from heavy steel and assembled to its
customer line-set schedules.
Muffler assemblies – Accuride fabricates, assembles and polishes muffler assemblies consisting of large diameter exhaust
tubing assembled with a muffler manufactured by a third party.
Crown assemblies and components – manufactures multiple styles of crown assemblies and components. A crown assembly
is the highly visible front grill and nameplate of the truck. These products are fabricated from both steel and aluminium and
are chrome-plated and polished.
Accuride also fabricates a variety of structural components/assemblies and chrome-plate and polish numerous other
components for truck manufacturers, bus manufacturers, OEM and aftermarket suppliers. These products include fenders,
exhaust components, sun visors, windshield masts, step assemblies, quarter fender brackets, underbells, fuel tank supports,
hood inner panels, door assemblies, dash panel assemblies, outrigger assemblies, diesel particulate filter housings, and
various other components.
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Sector activity Interviews& analysis PresentationsCompany newsCompetitors
External links:
Company site
YouTube
Status:Status: Public
TurnoverTurnoverFY 2012 sales: US$23,700m
Stock symbolStock symbol : AA
Alcoa, Inc
Aichi Steel
In May 2012, Toyota's affiliate Aichi Steel said that work at its new auto parts factory in Chonburi Province, Thailand has
been completed. It began full-scale production a month later.
According the report of The Mainichi, the company has invested approximately US$25.07m in its new auto parts factory.
The report also cited Aichi Steel saying that the Toyota group companies will get the propeller shafts for engines from the
plant.
Aichi Steel's existing plant in the country does not have the facility to make forged parts but the new auto parts factory
does have this provision. It will make up for Aichi Steel's other manufacturing bases in Philippines and China if production
gets affected by natural disasters, the company said.
In September 2011, Alcoa said it would expand its Davenport, Iowa, US rolled
products plant to meet rising demand from automakers. "More and more automotive
original equipment manufacturers are switching from steel to aluminium products as
they seek to increase the fuel efficiency, safety, durability and performance of the
cars they produce," the supplier said in a statement.
With help from an economic development incentive package from the Iowa
Department of Economic Development, the expansion, costing US$300m, will
increase auto-related output, adding 150 jobs to the existing 2,300 by the end of
2013.
Also in September 2011, Alcoa signed a Letter of Intent with China Power Investment (CPI) to produce high-end fabricated
aluminium products in China. In February 2012, Alcoa and CPI finalised this agreement. The venture, Alcoa CPI (China)
Aluminum Investment is majority owned and managed by Alcoa and based in Shanghai. The partners say the venture will
serve as a leading manufacturer of high-end fabricated aluminium products for the aerospace, automotive, commercial
transportation, consumer electronics and packaging markets in China. Terms of the agreement were not disclosed.
In January 2011, Alcoa announced that it intends to close or curtail approximately 531,000 metric tons, or 12% of its global
smelting capacity, to lower the company's position on the global aluminium cost curve and improve Alcoa's
competitiveness. Alcoa will permanently close its smelter in Alcoa, Tennessee, which was curtailed in 2009, along with two
of the six idled potlines at its Rockdale, Texas smelter, reducing Alcoa's global smelting capacity of 4.5 million metric tons
per year by 291,000 metric tons, or about 7%.
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On company overview page ofQUBE:
Sector activity Interviews& analysis PresentationsCompany newsCompetitors
External links:
Company site
YouTube
Google+
Status:Status: Public
TurnoverTurnoverFY 2012: EUR78.7bn
Stock symbolStock symbol : BAS
BASF SE
Aleris
Aleris is a major supplier of aluminium rolled and extruded products, aluminium recycling and specification alloy
manufacturing,. Its products are used by manufacturers in almost every industry. Headquartered in Cleveland, Ohio, the
company employs 7,300 people and operates 41 production facilities in North America, Europe and Asia.
In November 2012, Aleris signed a contract with FAW-Volkswagen to provide aluminium for several Audi models to be
produced in China. Aleris is supplying aluminium for the Audi A3 Sportback and Sedan models produced in Foshan, in
Guangdong Province, and the Audi Q5 produced in Changchun, in Jilin Province. Aleris has also increased its supply of
aluminium provided for the Audi A6 made in Changchun.
Asahi Kasei Plastics
In June 2012, Asahi Kasei Plastics opened a sales office in the Metepec Business Centre of Toluca, Mexico thereby adding to
the company's four warehouses in San Luis Potosi, Puebla, Torreon and Monterrey.
Asahi Kasei Plastics is expanding worldwide with new facilities, distributors and licence agreements to provide local service
and support to global customers. "Opening an office in Mexico is a strategic move for our company," said commercial
operations vice president, Ramesh Iyer. "Providing a high level of service is a top priority and this move will facilitate our
ability to better serve our clients in the region."
Asahi Kasei Plastics is a Michigan-based subsidiary of Asahi Kasei Chemicals Corporation and is one of the largest
manufacturing facilities for the company outside Japan. Additionally, Asahi Kasei Plastics is the largest glass reinforced
polypropylene manufacturer in North America.
BASF is in the process of expanding its presence in the Middle East region by building
a new plant to produce antioxidant blends (CSB) in Bahrain. CSBs are additives for
the production of polymers for the plastics industry. The new facility is scheduled to
be operational by end of 2012. BASF said the site will become one of the world's
largest CSB plants with an annual capacity of about 16,000 metric tons.
In September 2011, BASF and INEOS received approvals from the relevant antitrust
authorities to form a 50/50 joint venture, known as Styrolution. The partners are
combining their global business activities in styrene monomers, polystyrene,
acrylonitrile butadiene styrene, styrene-butadiene block copolymers and other
styrene-based copolymers as well as copolymer blends. The venture’s headquarters
will be located in Frankfurt, Germany with sites in Germany, Belgium, France,
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Sweden, Korea, India, Thailand, the US, Canada and Mexico. Styrene-based
copolymers are thermoplastic resins on the basis of the monomers styrene and
acrylonitrile. They are mainly used in the automotive and technical industries as well as for many everyday products.
In October 2011, BASF announced plans to build a production plant to produce tert.-Butylamine (tBA) in Nanjing, China. The
facility will be wholly-owned by BASF and will benefit from the integrated production system of BASF-YPC Co. Ltd.
Production is scheduled to begin in 2013. Located at the Nanjing Chemical Industry Park, the new tBA plant will have an
annual capacity of 10,000 tons and will mainly supply to the rubber chemicals and tyre industry in China.
In November 2011, BASF Japan said it will establish a new innovation structure in order to more efficiently develop and
promote technologies from Japan. In January 2012, the BASF Innovation Center Japan was established in the German
Industry Park, which is located in Yokohama's Midori-ku. The company’s engineering plastics technical centre in Yokkaichi
City, Mie Prefecture, will be relocated to the new centre. It will support all stages of the development process from concept
to design and testing of finished parts, says BASF.
BASF is building a new plant to produce Ultrason polyethersulfone (PESU), one of BASF's high-performance thermoplastics,
at the company's site in Yeosu, Korea. The annual capacity of the new plant is 6,000 metric tons. Production is expected to
begin by early 2014, creating 50 jobs. At present this specialty plastic is only produced at BASF's Ludwigshafen site in
Germany. Ultrason is the trade name for the BASF product range of polyethersulfone (Ultrason E), polysulfone (Ultrason S),
and polyphenylsulfone (Ultrason P). The product can withstand temperatures up to 220 degrees centigrade without altering
its properties and possesses outstanding chemical stability.
BASF is partnering with Bekaert (Belgium) and voestalpine Plastics Solutions (Netherlands). BASF is now working on the
development of thermoplastic components that are reinforced with steel cord fabrics and produced by means of injection
moulding. The partners are using and further developing EASI (Energy Absorption, Safety and Integrity) technology. Bekaert
contributes its expertise in the manufacture of steel cord fabrics to the cooperation, while voestalpine is responsible for the
processing technology and part production in injection moulding. BASF, for its part, is continuing to develop its crash-
optimised short or long fibre-reinforced polyamide specialties in the Ultramid product line for use in combination with the
steel cord inserts.
In August 2012, BASF Shanghai Coatings said it will invest in a new basecoat plant at the Shanghai Chemical Industry Park,
China. The new plant will increase the company's local production capacity for basecoat by 13,500 tons per annum.
Basecoat gives colour to and determines the visual impression made by the painted car body. The new coatings plant is
planned to start production in the first half of 2014.
In August 2012, BASF revealed it is expanding its network of Refinish Competence Centres. In Italy, an RCC is under
construction in Cesano Maderno. At the same time, plans for the construction of a new RCC in Atlanta, Georgia, US, are in
full swing. The RCC is scheduled to begin operations in mid-2013.
In September 2012, BASF opened a research lab for thermoplastic polyurethanes (TPU) in Wyandotte, Michigan. A team of
product developers, chemists and material scientists will work to discover new products for the American automotive,
construction, sports and leisure industries. Applications for these plastics include cables and tubes in the automotive,
mechanical engineering and construction industries.
In October 2012, BASF formed a technology partnership with SGL Group to develop a composite material based on a
reactive polyamide system and suitable carbon fibres, serving the production of thermoplastic carbon fibre-reinforced
composites. The material system is intended for use in the T-RTM process (Thermoplastic Resin Transfer Moulding) as well
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Bayer MaterialScience
as the reactive injection moulding process, and allows shorter processing cycles than conventional thermosetting RTM.
Also in October 2012, BASF acquired parts of Ciech's global TDI (toluene diisocyanate) business worldwide. Production
facility of Ciech's subsidiary Zachem, Poland, is not part of the transaction. TDI is a key component for the polyurethanes
industry. To a large extent it is used in the furniture segment (e.g. flexible foams for mattresses, cushions or wood coating)
as well as in the automotive industry (e.g. seating cushions and interior applications).
In October 2012, BASF opened its first Russian applications technology centre for polyurethane systems in Vsevolozhsk, near
St. Petersburg. Like the System House in Nishnekamsk, which went into operation in 2000, this site will also be a part of the
BASF joint venture Elastokam with the Russian company OAO Nishnekamskneftechim (NKNC). This centre provides
technical services and sales know-how for modern polyurethane systems to serve customers across Russia and other CIS
countries.
In January 2013, BASF said it will increase its annual global capacity for manufacturing the chemical intermediate 1,6-
hexanediol (HDO) by more than 20% to more than 50,000 tons per annum by 2014. BASF operates HDO production
facilities at its Verbund sites in Freeport, Texas, and Ludwigshafen, Germany. HDO is used in a number of parts, including
construction components for automotive lightweight applications.
Also in January 2013, BASF expanded its partnership with Nissan by supplying the automaker with coatings and paints for
the Pathfinder and Infiniti models at its Smyrna plant in Tennessee, US. BASF supplies Nissan with coating solutions from e-
coat and basecoat to clearcoat. BASF is also working on more streamlined technologies with Nissan in emerging markets
such as China.
In February 2013, BASF Shanghai Coatings broke ground on a new automotive coatings plant at the Shanghai Chemical
Industry Park. This production facility is scheduled to commence operation in early 2014.
Volkswagen used the 2013 Detroit motor show to present its CrossBlue concept car, a new generation of SUVs. The
automaker specially designed the car for the US and Canada, and the colour was developed by BASF's colour management
team in Würzburg in close collaboration with Volkswagen. For a number of years, BASF has been Volkswagen's reliable
partner worldwide, supplying products ranging from e-coat to clearcoat.
In March 2013, BASF completed its acquisition of parts of Ciech's TDI (toluene diisocyanate) business. The TDI production
facility of Ciech's subsidiary Zachem, Poland, is not part of the transaction. TDI is a key component for the polyurethane
industry. To a large extent it is used in the furniture segment (e.g. in flexible foams for mattresses, cushions or wood
coating) as well as in the automotive industry (e.g. in seating cushions and interior applications).
Also in March 2013, BASF launched a research initiative called 'North American centre for research on advanced materials'
through which it is collaborating with Harvard University, the Massachusetts Institute of Technology (MIT), and the
University of Massachusetts (UMass) Amherst. One goal of this initiative is to jointly develop new materials for the
automotive, building and construction, and energy industries. The cooperation is initially planned for five years. About 20
new post-doctoral positions will be created at the three universities. The ideas and topics to be researched will be decided
jointly by the researchers participating in the initiative. Topics already identified include micro- and nanostructured
polymers with new properties, as well as biomimetic materials that emulate nature.
Bayer MaterialScience is one of the world’s largest polymer companies. Its business
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Sector activity Interviews& analysis PresentationsCompany newsCompetitors
External links:
Company site
YouTube
Status:Status: Private
TurnoverTurnover2011 EUR10.8 billion
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Sector activity Interviews& analysis PresentationsCompany newsCompetitors
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Status:Status: Private
TurnoverTurnoverFY 2011: EUR7,106m
Benteler
activities are focused on the manufacture of polymer materials. Its main segments
served are the automotive, electrical and electronics, construction and the sports
and leisure industries. Bayer MaterialScience operates 30 production sites and
employs 14,700 people around the globe. Bayer MaterialScience is a Bayer Group
company.
In June 2011, Bayer MaterialScience began building the third phase of the expansion
of its polymer R&D centre in Shanghai, China. The centre has since been opened,
increasing staff numbers from 130 to 260. The expansion was part of a EUR1bn
investment plan.
In January 2012, Bayer MaterialScience began building a factory to produce
polyurethane coating raw materials at Chempark Leverkusen, Germany. The
products hexamethylene diisocyanate (HDI) and isophorone diisocyanate (IPDI) are
used primarily for automotive and industrial coatings. The company is investing
roughly EUR35m in the expansion of its production capacities. The plant is scheduled to open in late 2013.
Bayer MaterialScience used the 2012 UTECH show to unveil its Bayflex RIM Light Weight polyurethane system that can be
used to reduce the weight of finished components by up to 30 percent. With a density of just 0.9 kilograms per litre, this
material is even lighter than water. The supplier claims that this compact material offers design freedom for vehicle
construction and can be used to make components with a Class A surface that are to be finished with a high-grade coating.
It is processed using tried-and-tested RRIM (Reinforced Reaction Injection Molding) technology.
In October 2012, Benteler-SGL, a joint venture of Benteler Automobiltechnik and
SGL Group opened a factory to produce composite parts for vehicle bodies in Ort im
Innkreis, Austria. The supplier's product range now includes body shell components
such as side blades, doors and visible carbon components.
In November 2011, Benteler Automotive said it is investing some US$ 32.2m to
expand its Goshen, Indiana plant, creating 98 jobs. The company also announced
plans to create 80 more jobs by 2016, purchase US$22.1m in equipment, and invest
another US$7m on construction activity. Meanwhile, Benteler Aluminium also
announced plans to invest $7.6m to expand its aluminium extrusion operations at
Holland, Michigan plant. The facility is responsible for producing aluminium-based
sub frames, body structures and crash-management systems solely for the automotive industry. The expansion is mostly for
adding welding equipment and adding some capacity.
Biomer
Biomer has produced a polyhydroxybutyrate (PHB) formulation to be used in car interiors. The company claims its so-called
Biomer "P304", with mechanical properties resembling the base material "P226", has no component that causes bad odour
or fogging. It means that it can be used in the automotive industry unlike its predecessor. The production for the
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Sector activity Interviews& analysis PresentationsCompany newsCompetitors
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Status:Status: Public
TurnoverTurnoverFY 2011: EUR1,839m
Stock symbolStock symbol : CIE
CIE Automotive SA
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Cooper-Standard
biopolyester is currently underway. The new product is the outcome of a joint European Union ECOplast project, of which
Biomer is a part of. The project is also researching into the uninterrupted manufacturing of thermoformable sheets with
natural long fibre reinforcements, with P304 as a matrix material. The ECOplast project aims to induce the use of
renewable materials in the automotive industry.
Bodine Aluminum
Bodine Aluminum, originally known as Bodine Pattern, was founded in 1912 in St. Louis by Jesse R. Bodine to manufacture
patterns for various automotive customers. As the company expanded, it was the first in the region to heat-treat aluminium
castings for military and aircraft production. This led to diversified business opportunities within other industries. Toyota
Motor (TMC) purchased the company in 1990.
Today, Bodine produces engine brackets; carrier covers; cylinder heads and blocks; automatic transmission parts for Toyota's
engine and transmission plants in Alabama, Kentucky and West Virginia. It employs 1,100 at its three locations in Missouri
(Troy and St. Louis) and Tennessee (Jackson) and its total investment tops US$600m.
Cie Automotive is involed in a 50/50 joint venture agreement with Hispanoldes to
promote projects for the automotive component manufacturing industry. The first
project focuses on plastic components technology through the development of a
EUR1.1m manufacturing plant for the injection of plastic parts. The plant is located
in the Tangier free zone of Morocco. The second project is also located in Tangier,
consisting of the development of a production facility to manufacture injection
molds.
During 2012, Cooper-Standard Automotive invested some US$17.9m expanding its
plant in Goldsboro, North Carolina to produce rubber components, plastic seals and
trim.
In April 2011, Cooper Standard Automotive acquired USi from Japan’s Ikuyo. USi,
based in Rockford, Tennessee, provides a hard coating process for use in automotive
and industrial applications, including bright trim assemblies on vehicles produced by
a number of automakers, including Ford, GM, Honda, Hyundai, Nissan Motor and
Toyota. Through the sale, Cooper Standard has acquired USi's 109,000 square-foot
plant in Rockford and access to USi's unique coating process that allows for the
development of a number of surface finishes. Cooper Standard plans to spread USi's
technology and capabilities to its European businesses, where automakers are also
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Status:Status: Public
TurnoverTurnoverFull-year 2012 sales: EUR34.8bn
Stock symbolStock symbol : DD
DuPont (E. I. du Pont deNemours and Company)
Status:Status: Public
TurnoverTurnoverYear ended 31.12.11 US$2,853.3
Stock symbolStock symbol : COSHW
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Status:Status: Public
TurnoverTurnoverFY 2011: US$60bn (Group)
Stock symbolStock symbol : DOW
Dow AutomotiveSystems
seeking bright trim and hard-coated products to enhance overall vehicle appearance.
Dow Automotive Systems has developed a new glass coating for transportation
applications, including automotive original equipment, commercial vehicles and the
aftermarket.
The new material, known as BETASEAL PhX, is cured by ultraviolet light and ambient
moisture to form a durable coating that can stick to glass and polyurethane without
the use of primers. By using the UV-curable coating, glass can be tempered or
annealed with higher throughput and the coating can be applied post-furnace
thereby eliminating the necessity for ceramic enamel frit.
The coating can be applied in standard black or in multiple colours, such as white,
yellow, green, blue, red and metallic shades adding unique design advantages.
In August 2012, it was announced that Carlyle Group is on its way to buy DuPont's
performance coatings business for around US$4.9bn in cash. According to Proactive
Investors, the deal would be finalised in the first quarter of 2013. Carlyle will be
investing from its equity in fifth Carlyle Partners Fund and the Carlyle Partners lll
Vehicle. The company hopes to accelerate DuPont Performance Coating's growth in
emerging markets, especially China and Brazil.
In December 2011, several buyout firms were preparing to participate in the roughly
US$4bn auction for the DuPont unit that makes automotive finishes and industrial
coatings, people familiar with the matter have said. DuPont is reviewing the sale of
its performance coatings business, sources previously told Reuters, as the company
reconsiders its focus after having grown from a maker of explosive black powder into
a global materials company active in the chemical, food and agricultural sectors.
Major private equity firms have expressed early interest in the deal, according to the
latest sources. KKR & Co, Bain Capital, TPG Capital and Onex Corp are among those
who have made preliminary inquiries about the sale and talked to banks about
financing a potential deal, these people told Reuters. While private equity firms have shown strong early interest in the
business, it remains yet to be seen if potential trade buyers such as PPG Industries Inc and AkzoNobel NZ will also
participate in the auction, the report noted.
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Facebook (Faurecia NorthAmerica)
Status:Status: Public
TurnoverTurnoverFY 2012: EUR17.364.5m
Stock symbolStock symbol : FR00001211
Faurecia
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Freudenberg & Co. KG
In 2012, DuPont and Shanghai 3F New Material formed a 50/50 venture located in Changzhou to produce
polytretrafluoroethylene (PTFE) and perfluorinated ethylene propylene copolymer resins. The partners expect to bring a
technological breakthrough to the Chinese fluoropolymer industry. PTFE's low frictional properties enable it to be used in
areas such as plain bearings, gears, slide plates etc, where sliding action of parts is needed.
In February 2013, DuPont completed the sale of DuPont Performance Coatings (DPC) for US$4.9bn to the Carlyle Group.
DPC is a global supplier of vehicle and industrial coating systems. DuPont said it remains committed to serving the
automotive industry following this transaction and expects to generate more than $3bn in sales of advanced materials to
the auto industry annually.
In July 2012, Faurecia acquired the automotive business of Sora Composites. The
division specialises in the manufacture of composite plastics and the use of glass and
carbon fibre for automotive applications. The acquisition positions Faurecia for
expected growth in the use of 'new materials' in automotive - growth being driven
by improved manufacturing techniques, higher volumes and the benefits of lighter
materials in end use. The two plants affected by the acquisition are located in
Theillay and Saint-Méloir-des-Ondes, with the operational headquarters based in
Changé (all three sites in France). This business generates annual sales of around
EUR70m with a total staff of around 500. Sora Composites produces body and
structural parts for customers that include Renault, PSA Peugeot Citroën, Aston
Martin, Audi, Lotus and McLaren Automotive.
Faurecia has been conducting research into bioplastics derived from 100% natural
materials since 2006 (BioMat project). In November 2012, Faurecia entered into a
partnership agreement with Mitsubishi Chemical Corporation to co-develop
bioplastics designed for mass-production for use in automotive interiors. Faurecia
plans to develop a full range of bioplastics, which are set to see a boom in the 2015
to 2020 period. This project builds on several years of development work carried out jointly with BioAmber, a specialist in
bio-based succinic acid technology.
In April 2012, Freudenberg Far Eastern Spunweb said it is making a two-digit million
investment in a new production line for PET spunlaid nonwovens in Taiwan.
Production is scheduled to commence in approximately two years. The Tayuan
facility will then serve customers in the markets such as automotive interiors and
filters. Bruce Olson, CEO of Freudenberg Nonwovens said, "With this new
investment, we are confirming our strong commitment to our global spunlaid
business and reinforcing our position as market leader on the Asian market."
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Status:Status: Private
TurnoverTurnoverFY 2011: EUR6,007m (Group)
Gestamp Automocion
Gestamp is active internationally in the supply of metal components, modules and systems for the automotive industry
sector and has as its core business the automotive supply division Gestamp Automoción.
In July 2011, Gestamp Automocion had its proposal cleared by the European Commission to acquire ThyssenKrupp Metal
Forming. The Commission's investigation confirmed the merged entity would continue to face competition from a number of
other strong competitors and customers would still have sufficient alternative suppliers in all markets concerned. The EC
examined competitive effects of the proposed acquisition in affected markets for the manufacture and supply of structural
chassis assemblies, foot controls, hinge systems and steel service centres used in the automotive industry as input for
automotive components. Its conclusion was the transaction would not significantly impede effective competition in the
European Economic Area or any substantial part of it. TKMF is a group of companies active in the manufacture and supply of
body and chassis stampings, as well as assemblies to the automotive sector.
During 2012, Gestamp invested some US$100m at its South Charleston stamping plant to restart producing metal structure
for vehicles.
Henkel
Henkel says in response to requirements of higher temperature and vibrational energy automotive sensor applications, it has
developed a new portfolio of silicone-based electrically conductive adhesives (ECAs) to address harsh environmental
conditions. The supplier maintains the Loctite Ablestik ICP 4000 series of ECAs withstand operating temperatures as high as
200C and deliver the flexibility required to cope with significant vibration. Traditionally, older-generation epoxy-based ECAs
have been used for certain automotive sensor applications. As technology has progressed however - and sensor proximity to
the heat and vibration source - the engine block - has become closer - epoxy systems are challenged to maintain long-term
flexibility and conductivity.
Typical temperature, humidity, shock and storage testing evaluates ECA performance for a period of 1,000 to 1,500
cycles/hours. When validating the properties of the Loctite Ablestik ICP 4000 series materials, however, Henkel maintains
testing time periods were doubled. "The trend toward increasing electronics content in automobiles with sensor location
moving ever-closer to heat and vibration-producing sources will only accelerate," said Henkel Electronic Assembly adhesives
global product manager, Tom Adcock. "In order to progress emerging technology requirements, new materials such as these
latest silicone ECAs from Henkel will be critical."
Key Plastics
In February 2012, Key Plastics completed a deal under which it sold a portion of its European operations in a management
buy-out. Innovative Components Technologies GmbH (ICT) of Germany has since become the owner and operator of formerCopyright 2013, just-auto Generated on 11 April 2013 20
buy-out. Innovative Components Technologies GmbH (ICT) of Germany has since become the owner and operator of former
Key facilities in Wachtersbach, Lennestadt and Kierspe, Germany; Tachov, Czech Republic; and Borja, Spain.
Key Plastics retains operations, tied to its core businesses, at 12 locations in seven countries. Operations in Europe now
consist of manufacturing and engineering facilities in Leiria and Vendas Novas, Portugal; Lohne, Germany; and Janovice,
Czech Republic.
Key Plastics also operates in the US, China, Japan and Mexico. Its core businesses include the engineering and production of
automotive handles, bezels and clusters, mechanisms and air registers, highly decorated trim components, and precision-
moulded engine compartment products.
Kobe Steel
Kobe Steel Ltd is one of Japan's major steel makers as well as a major supplier of aluminium and copper products. Its other
business segments consist of wholesale power supply, machinery, construction machinery, real estate, and electronic
materials and other businesses.
In 2011, Kobe Steel entered into a joint venture with China's Anshan Iron and Steel Group Corp to make cold-rolled
advanced high strength steel sheet used in vehicles. Cold-rolled high strength steel generally has a tensile strength of 340
MPa or more. Advanced high strength steel, noted for its formability, has a tensile strength of 590 MPa or higher. A
continuous annealing line is mainly used to make advanced high strength steel sheet.
During 2011 and 2012, Kobe Steel expanded the joint production capacity of its Chinese joint venture, Kobe Special Steel
Wire Products (Pinghu) (KSP). The other joint venture partners are Shinsho Corporation, Osaka Seiko and Meihoku Kogyo.
KSP began operations in 2009. Since then, vehicle production in China has continued to increase and consequently demand
for cold heading (CH) steel wire has steadily grown. CH wire, made from special steel wire rod, is manufactured into high-
strength nuts and bolts for use in vehicles. KSP has added two wire drawing machines to the existing three units, yielding a
total of five machines. Wire drawing capacity has increased from the current 2,100 metric tons per month to 3,350 metric
tons per month. An additional Short Time Cycle annealing furnace has also been installed for a total of two units. To house
the new equipment, a 3,100-square-meter building was constructed.
Kobe Steel's other recent investments include:
Capital investments of some US$464m to enhance the hot-metal treatment capacity at its Kakogawa Works and Kobe
Works and the heat treatment capacity for steel plate at the Kakogawa Works to strengthen the competitiveness of
the company's steel facilities.
Increase the production capacity of its subsidiary in China that makes aluminium forgings for automotive suspensions.
Kobe Steel has installed an additional forging press, as well as newly construct melting and casting equipment at Kobe
Aluminum Automotive Products (China).
Join forces with Jiangsu ALCHA Aluminium, a major producer of aluminium rolled products in China, to expand its
aluminium business in China. Kobe Steel and ALCHA have signed a letter of intent to establish a joint venture in
Baotou, Inner Mongolia to produce and sell aluminium coil and sheet. The joint venture produce and sell mainly
aluminium coil and sheet for vehicles and beverage cans. Production capacity at the joint venture will be approximately
200,000 metric tons per year.
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In January 2012, Kobe Steel established a company in Foshan, Guangdong Province, China to make steel wire for use in
springs. The new company, called Kobelco Spring Wire (Foshan) (KSW), will begin operations in the first half of 2013. To
shorten construction time and reduce investment costs and overhead, KSW will be located within the premises of sister
company Kobe Wire Products (Foshan). KSW will receive technical assistance from Shinko Wire Company, and Suncall
Corporation for the secondary processing of steel wire rod. KSW was established in January 2012. It will have a production
capacity of 600 metric tons per month. The company is a wholly owned subsidiary of Kobelco Holding (China), Kobe Steel's
China headquarters. When KSW begins operating, plans call for steel wire, which is exported, to shift to local production to
meet market demand for automotive springs in China. Through the establishment of KSW, Kobe Steel aims to meet the
growing demand for high-quality steel wire in China.
In April 2012, Kobe Steel started construction for a spring steel plant, Kobe Xinque Spring Steel, in the Nanhai National
Ecological Industrial Demonstration Zone, Foshan, China. Foshan Daily reported that the spring steel produced from the
plant will mainly be used for automobile purposes. The plant is expected to have a capacity of 12,000 metric tonnes. The
construction was completed in October 2012.
In July 2012, Kobe Steel established two 100 percent owned companies, one in Europe and the other in the Middle East, to
expand the global marketing and servicing of its compressors. Kobelco Machinery Europe is located in Munich, Germany to
strengthen the marketing of Kobe Steel's nonstandard compressors in Europe. It also procures parts for use in the
manufacture of compressors in Japan. The new subsidiary is capitalised at EUR100,000 and employs eight people. Kobelco
Machinery Middle East is located in Dubai, United Arab Emirates and provides after-sales services for nonstandard
compressors sold in the Middle East. The unit is capitalised at US$272,186 and employs five people.
Also in July 2012, Steel Authority of India (SAIL) and Kobe Steel signed the final draft of agreement to form a joint venture
in the country. The joint venture has been named SAIL-Kobe Iron and the proposed facility will get an investment of around
US$272m.The new joint venture would utilise the Iron Making Technology Mark-3 (ITmk3) for making iron nuggets from iron
ore fines and non-coking coal to be used in steel-making Electric Arc Furnaces (EAFs). Kobe would provide the technical
know-how for the operation. The new 0.5 metric tonne per annum facility would be included in SAIL's Alloy Steel Plant in
Durgapur. Earlier in 2010, Kobe and SAIL had signed a Memorandum of Understanding to establish a 1.2 metric tonne per
annum gas powered steel plant meant to produce steel for the automotive sector.
In November 2012, Kobe Steel’s US subsidiary, Kobe Aluminium Automotive Products (KAAP) began building a production
line to produce cast aluminium bars for use in car air conditioning compressor parts. KAAP is investing some US$11m in the
new line, which will go into operation in August 2013. Located in Bowling Green, Kentucky, KAAP currently manufactures
aluminium forgings for automotive suspensions. In Japan, Kobe Steel makes cast aluminium bars for air conditioning
compressors at its Chofu Works in Shimonoseki, Yamaguchi Prefecture in western Japan. The cast bars are supplied to
Toyota Industries. Toyota Industries has established a company in the United States called Toyota Industries Compressor
Parts America to manufacture car air conditioning compressor parts. Established in February 2012 in Pendergrass, Georgia,
the company will begin production in September 2013 and will source all of its cast aluminium bars from KAAP.
In March 2013, Kobe Steel moved to a new head office building in Kobe. The new building is located in HAT Kobe, a
redeveloped area east of the city centre of Kobe. The old head office consisted of the Shinko Building constructed in 1986
and the Shinko Building Annex built in 1996.
Lanxess
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Magna International Inc.
Lanxess is a specialty chemicals company employing around 16,900 employees in 31 countries. The company is currently
represented at 49 production sites worldwide. The core business of Lanxess is the development, manufacturing and
marketing of plastics, rubber, intermediates and specialty chemicals. The group’s 13 business units are grouped into the
three segments Performance Polymers, Advanced Intermediates and Performance Chemicals.
In March 2012, Lanxess started building its neodymium polybutadiene rubber (Nd-PBR) plant in Singapore. The EUR200m
plant will produce some 140,000 metric tons annually in Jurong Island Chemical Park. The facility will be the largest of its
kind in the world and serve the growing market for "Green Tyres", especially in Asia. About 100 jobs will be created. The
plant is expected to commence operations in the first half of 2015.
Also in March 2012, Lanxess opened a material testing centre at its Dormagen site in Germany. The testing equipment
installed in the new centre is being used to determine the material data for the most important load scenarios for
thermoplastic materials, such as their fatigue, crash and creep properties. The unit is designed to allow the testing not only
of very stiff materials such as reinforced polyamides and nylon composite sheet as well as flexible materials such as
polyamides for automotive charge air tubes.
In April 2012, Lanxess opened a new formalin production plant at its Krefeld-Uerdingen site in Germany. On 24 April, the
head of Lanxess' Advanced Industrial Intermediates business unit, Hubert Fink, and Krefeld's mayor, Gregor Kathstede,
officially opened the state-of-the-art plant. Formalin is a feedstock for trimethylolpropane (TMP), a trivalent alcohol used
for a number of products in automotive. The investment totals around EUR18m, creating five jobs at the site. New formalin
and methanol tanks have been constructed along with the plant and its 38-meter high tower on an area totalling 1,000
square metres.
In June 2012, Lanxess said it is investing EUR75m in the construction of a new plant for high-tech plastics in Antwerp,
including those for automotive applications. The facility for polyamide plastics is designed for an annual capacity of 90,000
metric tons and scheduled to begin operation in the first quarter of 2014.
Lanxess is investing in its production site for high-performance rubber in La Wantzenau, France. The company plans to invest
at least EUR40m by 2020 to further enhance productivity and energy efficiency.
Lanxess produces nitrile-butadiene rubber (NBR) in the plant, which is used primarily in the automotive and construction
industries. The plant is the largest of its type in the world with an annual capacity of more than 100,000 metric tons. The
group manages its entire global NBR rubber business from La Wantzenau. The Alsace site is also home to Lanxess' worldwide
research and development activities for NBR rubber.
Lanxess is also to open a new compounding plant in Gastonia, North Carolina.
In September 2012, Lanxess acquired Germany’s Bond-Laminates, a specialist in developing and producing custom-made
plastic composite sheets that are reinforced with materials such as glass fibres. This composite technology is sold under the
brand TEPEX. Financial details were not disclosed.
Magna International’s Exterior and Interior Systems business develops and
manufactures a variety of parts, including front and rear end fascia systems, exterior
trim, class A composite panels, top systems, engineered glass, under hood and under
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Competitors
External links:
Company site
YouTube
Status:Status: Public
TurnoverTurnoverFY 2012: US$30.84bn
Stock symbolsStock symbolsMGA, MG
body components, and structural components.
Magna Exteriors and Interiors (MEI) is working with Zoltek in providing carbon fibre
composite parts and systems for high-volume automotive applications to support
automakers' lightweighting initiatives. The partners have developed a low-cost
carbon fibre sheet moulding compound. The jointly developed carbon fibre SMC
material uses Zoltek's Panex 35 commercial carbon fibre combined with Magna's
EpicBlendSMC formulations and production expertise. The material, named
EpicBlendSMC EB CFS-Z, is part of MEI's EpicBlendSMC product line and allows
Magna to offer manufacturers an expanded range of lightweight parts, sub-systems
and semi-structural applications for automotive as well as commercial truck and
other markets.
Merger and acquisition activity
In February 2011, Cosma International acquired the Dürbheim facility of Acument GmbH & Co oHG. Acument - Dürbheim is
a supplier of stamped high-strength extrusions for vehicle makers, including Daimler, BMW, General Motors, Ford and
Renault.The acquisition of the Dürbheim manufacturing facility, which is located in southwest Germany near Stuttgart,
strengthens Cosma’s market position and diversifies its customer portfolio in the extrusion segment.
In May 2011, Cosma International entered into a joint venture in China with Guangzhou Automobile Group Component Co
Ltd. The new joint venture, named Changsha Cosma Automotive, will be located in Changsha City, Hunan Province, China.
The partners plan to establish a manufacturing facility there that will employ 550 people at full capacity and produce major
body and chassis components and structural assemblies. Construction of the facility, which will be one of the largest body
stamping and assembly plants in the area, began in 2011 with start of production targeted for 2012. The first products to be
manufactured at the facility will be for a GAC-Fiat vehicle programme. Cosma International manufactures metal body
systems, components, assemblies and modules, including complete vehicle frames, chassis systems and body-in-white
systems. It operates 52 manufacturing facilities and 25 product development and engineering centres worldwide.
In August 2011, Magna Exteriors and Interiors formed a joint venture to purchase an existing injection moulding and painting
facility located in Wuhu, a city in the Anhui province of southeastern China. The three-party joint venture, called MCC
Wuhu Exteriors, consists of Magna Exteriors and Interiors (51%), CAIP (Changshu Automotive Trim, 34%) and Chery Tech
(15%). The 300,000 square foot manufacturing plant, which booked revenue of about US$43m in 2010, employs about 600
people and supplies its primary customer Chery Auto with front and rear fascias. "Consistent with our strategy to pursue
growth in emerging markets, this opens the door for our exteriors and fascia business in China," said Bob Brownlee, president
of Magna Exteriors and Interiors in North America and Asia. "Having established a presence in China with our interior
components and systems during the past several years, we now have a foundation from which we can begin a growth phase
for our exteriors business in the region as well."
In September 2011, Cosma International acquired Grenville Castings (2007) Ltd, a structural casting supplier of aluminium
components for the automotive, heavy truck and recreational markets. Magna says the move will allow Cosma to become a
global manufacturer of aluminium structural castings in all major geographic markets. The acquisition will also support
Cosma's global launch of an automotive chassis programme which is scheduled to start production in 2014. Production will
be supported through both existing and new manufacturing facilities, says Magna.
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In November 2011, Cosma International signed an agreement to acquire the BDW Technologies Group. BDW is develops
and manufactures vacuum high-pressure aluminium die casting. On completion, Cosma will acquire two operations in
Germany, one in Poland and the other in Hungary. BDW's customers include Volkswagen, Audi, Porsche, Mercedes-Benz,
Ferrari and ZF. This acquisition will strengthen Cosma's ability to deliver lightweight solutions for complex body-in-white
structural and chassis components in steel, aluminium or aluminium-steel hybrid to customers around the world.
In December 2011, Magna International's Cosma International closed a deal with ThyssenKrupp Automotive Systems to
acquire ThyssenKrupp Automotive Systems Industrial do Brasil Ltda. (TKASB) which produces and assembles chassis
structural components and modules for several Brazilian automotive customers from four plants. Cosma has acquired TKASB
and all of its operations, which consist of four manufacturing facilities located in Sao Bernardo do Campo, Ibirité, Camacari
and São José dos Pinhais. TKASB employs approximately 770 employees at the four plants. Current production customers
include Ford, Fiat, Renault-Nissan, Honda and PSA. The acquisition expands Cosma's global footprint and positions the
company to become a leading metal forming and chassis system supplier partner to OEMs throughout South America,
Magna said.
Infrastructure
In September 2010, Magna International opened three facilities in St Petersburg, Russia. Two of the facilities operate as
Cosym, a joint venture started in 2006 between Cosma International, an operating unit of Magna International and
automotive metal-forming supplier, and Shin Young Co, a Korea-based supplier of major stampings, welded assemblies and
tooling. The Cosym stamping and assembly plant in Shushary currently has 170 workers and produces body, chassis and
energy-management systems for OEM customers such as Hyundai, General Motors, Nissan and Volkswagen. The Cosym
assembly and sequencing plant in Kamenka is a Hyundai-dedicated production site that currently has 50 employees
producing body sub-assemblies based on parts stamped in Shushary. Once the Cosym facilities reach full capacity, the
partners expect a total of 650 employees between the two locations covering a production area of 54.000 square meters in
total. In addition to the two Cosym facilities, Magna also opened of a facility in Kolpino which has 25 employees producing
exterior and interior components for OEM customers, including Ford and Nissan.
In 2011, Magna International opened two new plants in Sao Paulo, Brazil. Magna’s body and chassis unit, Cosma
International, opened a plant while its seating division provides seats for a General Motors model line at another plant.
Magna employs around 900 people at the two plants. More specifically, Cosma’s new facility produces stamped and welded
assemblies for global automakers. Magna Closures Brazil serves all global automakers operating in South America, including
business in the heavy truck segment and employs 750 people.
In 2012, Magna began operated at a new facility in San Luis Potosi, Mexico. The US$100m facility is a division of Cosma
International, an operating unit of Magna and a global automotive body and chassis system supplier. This facility produces
stamped and welded assemblies for various automakers.
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External links:
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Status:Status: Public
TurnoverTurnoverFY 2012 consolidated revenue:US$2.9bn
Stock symbolStock symbol : MRE
Martinrea InternationalInc.
Martinrea International Inc is a major manufacturer of steel and aluminium metal
parts, assemblies and modules and fluid management systems focused mainly on
the automotive sector.
In May 2011, the company signed a purchase and transfer agreement for all of the
assets of Honsel AG, a German-based supplier of aluminum components for the
automotive and industrial sectors. The transaction is reported to be valued at
EUR130m. Martinrea has partnered with Anchorage Capital Group, LLC in the transaction. Martinrea will own 55% of the
entity purchasing Honsel, with Anchorage owning the remaining 45%.
Honsel develops and manufactures complex aluminum and magnesium products using production technologies including
high pressure die-casting, permanent mold and sand casting as well as extruding and rolling. Honsel produces four product
lines:
engine products such as engine blocks, cylinder heads and oil pans;
transmission products, such as housings and control parts;
suspension products, such as engine cradles; and
body parts, such as front boards and extrusion profiles.
Honsel has seven production sites globally, including four in Germany, and one each in Spain, Mexico and Brazil, employing
4,000 people. Honsel's head office and largest operation is located in Meschede, Germany. Honsel also has plants in
Nuremberg, Soest and Nuttlar in Germany, as well as Madrid, Spain; Queretaro, Mexico and Monte Mor, Brazil.
Honsel is presently in insolvency proceedings in Germany. Pursuant to the insolvency process, offers for the Honsel assets
were sought from interested bidders. After extensive diligence and negotiation, Martinrea, with its partner Anchorage, was
selected by the administrator in the insolvency proceedings to finalize a purchase agreement.
Minda Corporation
India's Minda Corporation is in the process of expanding capacity at its existing automotive plastic manufacturing unit in its
home country and plans two more plants by 2017. It is also expanding overseas with acquisitions. “We are expanding the
Chaken, Pune plant for completion by June 2012. We have decided to set up two more units - in Chennai, Tamil Nadu, by
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the end of 2013 and the second one at Sanand, Gujarat, by the end of 2014,” business development chief Sandeep Aggarwal
told just-auto. He added the expansion and the two new plastic interior and exterior components factories would cost about
US$50m.Sandeep noted: “Composite plastic is as strong as steel or metal and that is the reason plastic is increasingly
replacing steel or metal components in the automotive sector around the world.”
Minda supplies plastic oil sumps for Mercedes-Benz Actros trucks, replacing grey iron parts. The company supplies 100% of
the interiors of the Chevrolet Sail hatchback, among other vehicle models.
Minda is a key maker of automotive interiors for Indian OEMs, supplying parts like the central console, seat rim and backrest
for the VW Polo and Vento, central consoles for the Skoda Fabia hatchback and Tata Sumo Gold, air vents for Fiat's Linea
sedan and parts for Maruti Suzuki's recently upgraded Swift.
Minda has also extended its plastics footprint in Europe with a series of acquisitions in the past five years. Minda KTSN
Plastic Solutions (MKPS) is located at Pirna, near Dresden, Germany, and has over 50 years' experience developing and
making plastic parts and assemblies.
Minda Schenk Plastics Solutions specialises in car interiors and is one of the key players in Europe supplying global players
like Daimler. It is based in Esslingen, Germany, with plants there and in Liberec, Czech Republic. Minda has also acquired Alu
Automotive in Poland and Axis Automotive in Kongin, Germany.
NanoSteel Company
In August 2012, General Motors Ventures invested an undisclosed amount in the NanoSteel Company which specialises in
nano-structured light weight steel materials.
Following the development of patented alloys, NanoSteel has created a new class of steel that allows automotive engineers
and designers to reduce weight through the use of thinner, higher strength gauges while maintaining the structural integrity
needed for safety. The new steel design is described as an alternative to other light weight materials which may cost more,
require new investment in parts production and have performance limitations.
GM Ventures, the GM subsidiary which invests in promising automotive technologies, joined other lead shareholders -
EnerTech Capital and Fairhaven Capital Partners - and five existing investors to complete a financing round. Terms of the
investment were not disclosed in a GM statement.
Privately held NanoSteel is based in Providence, Rhode Island, with R&D and engineering facilities in Idaho Falls, Idaho.
Novelis
Novelis is a major producer of rolled aluminium for the global automotive market and the provider of aluminium sheet to
the Chinese vehicle industry.
In April 2012, Novelis entered into an agreement with the Changzhou National Hi-Tech District to build the company's first
automotive sheet manufacturing facility in China. The agreement includes land use rights to more than 160 acres. The
wholly owned, US$100m plant will have a capacity of 120,000 tonnes per year and is expected to be commissioned for
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Status:Status: Public
TurnoverTurnoverFY 2012 sales - US$15.2bn
Stock symbolStock symbol : PPG
PPG Industries
operation in late 2014.
The company plans to ship rolled aluminium coils manufactured at its South Korean operations to the new facility in
Changzhou for heat treatment and finishing before delivery to automotive customers within China as well as to export
markets. Current Novelis auto sheet customers include Audi, BMW, Chrysler, Ferrari, Ford, GM, Hyundai, Jaguar, Land
Rover, Mercedes-Benz, Porsche, and Volvo.
Novelis expects demand for aluminium in the global automotive sector to grow at a compound annual rate of 25% over the
next five years as auto manufacturers look for ways to make their vehicles more fuel efficient. The move into China will
position Novelis as the only aluminium sheet supplier capable of serving automotive customers in all major markets of the
world. Novelis is the leader in automotive sheet supply in Europe where light-weight aluminium has become a popular
alternative to steel for vehicle makers. And to meet growing demand in North America the company is expanding its
footprint there with a US$200m project to increase automotive sheet capacity by 200,000 tons annually.
Oerlikon Balzers
In November 2012, Oerlikon Balzers opened its tenth coating centre in Wuhan, China. Over the past 20 years Oerlikon
Balzers expanded its global network of coating centres and capacities continuously. Whereas in 2000 the company operated
41 centres in 17 countries, the number now reached 89 in 33 countries. The Asian market played a crucial role in this strong
increase, says the company. The latest coating centre is located in Wuhan is also the home of China's one of the largest
domestic automotive companies, including the Dongfeng Group and its suppliers.
PPG Industries Inc is a diversified manufacturer that supplies paints, coatings, optical
products, specialty materials, chemicals, glass and fibre glass. PPG is organised into
six business segments, namely: Performance Coatings; Industrial Coatings;
Architectural Coatings – EMEA (Europe, Middle East and Africa); Optical and
Specialty Materials; Commodity Chemicals; and Glass. Its Performance Coatings
segment incorporates its Automotive Refinish business which provides coatings for
the automotive repair market. Its Industrial Coatings segment incorporates its
Automotive OEM Coatings business which provides coatings and services to
passenger car and light truck manufacturers.
Products
PPG Industries' automotive refinish business is offering its HS Express Clearcoat P190-6800, a 2.1 VOC (volatile organic
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compound) air-dry compliant clearcoat. The clearcoat is part of the company’s so-called Nexa Autocolor line of products
and designed for use with its Aquabase Plus system. "Not only does this new clearcoat fit well into the Aquabase Plus
system, it also displays exceptionally fast process speed, which means significant time savings over conventional
clearcoats," said Jeff Griffin, PPG compliant segment manager, North America. "And with no bake cycle required, P190-
6800 saves energy costs because there is no need to heat the spray booth. This is definitely a critical productivity advance
for the collision industry." The company adds that P190-6800 is suitable for both spot repairs and panels in a variety of
operating environments.
Merger and acquisition activity
In May 2011, PPG Industries completed its acquisition of certain assets of Equa-Chlor Inc, a producer of chlorine, caustic soda
and muriatic acid, based in Longview, Washington for US$27m. PPG now operates the Longview manufacturing plant, with
65 employees, which produces about 220 tons of chlorine per day. In addition, the railcar fleet formerly owned by Equa-
Chlor has been integrated into PPG's rail delivery system, enabling PPG to optimise overall railcar use while reducing future
capital requirements and logistics costs. PPG currently manufactures chlor-alkali and derivates products in Lake Charles, La.;
Natrium, W.Va.; Beauharnois, Quebec, Canada; Longview, Wash.; and through a majority-owned subsidiary in Kaohsiung,
Taiwan.
In June 2011, PPG Industries acquired Ducol Coatings South Africa, which has served as an importer and distributor of PPG's
automotive refinish products in South Africa since 2003. Ducol Coatings, based in Krugersdorp, north west of Johannesburg,
was formed in 1990 and has been active throughout South Africa and in Namibia. PPG continues to use the Ducol brand, as
well as Ducol Coatings' former franchisee and distributor network, giving PPG access to a distribution network in the South
African market.
In January 2012, PPG Industries completed its acquisition of the coatings businesses of Colpisa Colombiana de Pinturas and
its affiliates, including Colpisa Ecuador. Financial terms were not disclosed. In acquiring Colpisa, PPG becomes the only
major coatings supplier with a direct automotive OEM coatings manufacturing presence in Colombia and a supplier of
automotive refinish products in Colombia with an established distribution network. Colpisa has been a technology licensee
of PPG automotive OEM coatings since 1996 and a distributor of PPG automotive refinish products since 2004. PPG now
operates Colpisa's coatings manufacturing facility in Itagüí, Colombia, which employs about 315 people. Colpisa was
founded in 1973 and manufactures and distributes coatings for OEM, automotive refinish and industrial customers in
Colombia and Ecuador.
Infrastructure
In June 2011, PPG Industries started operations at a new facility in the Zhangjiagang Yangtze International Chemical
Industrial Park, Jiangsu Province, marking the first resin production plant in China. With initial production capacity of 27,000
tons, the plant is supplying resin products to PPG coatings plants and other customers in the region. More specifically, this
facility produces finished electrodeposition resins for use in the manufacture of automotive and industrial electrocoat
products. PPG also operates resin-production facilities in the US, Europe, Brazil, Australia, South Korea and Mexico.
In May 2012, PPG Industries' automotive refinish operations in China relocated to a plant in Songjiang, Shanghai.
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TurnoverTurnoverFY 2012 sales: US$2.9bn
Stock symbolStock symbol :
Samvardhana MothersonGroup
PT Astra Otoparts
In September 2012, Indonesia’s largest automotive components group, PT Astra Otoparts, announced the establishment of
two new wholly-owned subsidiaries. One of the companies - PT Autoplastik Indonesia - plans to build a new plastic
components plant in Karawang, West Java, near Toyota’s new small car plant. The second company, PT Velasto Indonesia,
will produce rubber based components including hose and drive belts for passenger cars and motorcycles in Purwakarta, also
in West Java. Astra Otoparts, which is controlled by the country’s largest automotive distributor, PT Astra International, now
comprises 19 separate subsidiary companies.
SMG operates 16 manufacturing plants which specialise in polymer processing,
manufacturing of electrical components, automated painting and the assembly of
complete systems. The group employs 4,400 people at its sites located in the
following countries:
Australia -- Adelaide
China – Bejing, Yancheng, Shanghai
France – Dammarie-Les-Lys
Germany – Stuttgart
Hungary – Mosonszolnok, Gyor
India – Noida, Chennai
Japan – Nagoya City
Mexico – San Luis Potosoi
South Korea – Ochang, Puchon
Spain – Epila
UK – Portchester
US – Marysville, Detroit
In July 2011, Moherson Sumi Systems Ltd said it would buy an 80% stake in Germany's Peguform Group for EUR141.5m.
Motherson Sumi said it would acquire the stake through a special company in which it will hold a 51% stake while group firm
Samvardhana Motherson Finance Ltd will hold the remainder. Motherson is buying the stake from Austria's Cross Industries
AG, which will continue to hold 20% of Peguform. The Peguform deal comes after the firm's acquisition of Visiocorp, the UK
based manufacturer of rear-view mirrors, in 2009, cementing its presence in Europe. Gaining control of Peguform will give
the company a big foothold in business with Volkswagen, BMW and Daimler.
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Showa Denko
Showa Denko (SDK) plans to open an aluminium casting plant in the state of Johor, Malaysia by the end of 2014. In addition
to an integrated aluminium casting/forging facility at Kitakata, Fukushima Prefecture, Japan, SDK operates plants in
Portugal and Singapore producing forged aluminium parts, mostly for the global automotive market. Based on its
proprietary continuous casting process, SDK makes cast aluminium rods with a metal structure to produce forged aluminium
parts. The main applications include air conditioner compressor components, pistons and suspension parts. SDK also sells
cast aluminium rods for subsequent forging.
In February 2013, Showa Denko's board of directors took the decision to merge with its wholly-owned subsidiary Marusho
Kogyo. Marusho Kogyo, as a wholly owned subsidiary of SDK, had a shipment base for liquefied ammonia and industrial
aqueous ammonia in Soma District, Fukushima Prefecture, and sold these products. As a result of the tsunami that followed
the Great East Japan Earthquake, however, the shipment base was damaged, and Marusho Kogyo suspended its operations.
This time, SDK decided to reconstruct the shipment base, and to merge with Marusho Kogyo for the purpose of ensuring
stable supply in the Tohoku region based on an integrated system of production and sale.
Solvay
Solvay is an international chemistry group. The group is headquartered in Brussels and employs 16,800 people in 40
countries.
Solvay is in the process of building a specialty polymers production plant for SOLEF Polyvinylidene Fluoride, TECNOFLON
Fluoroelastomers and their essential monomer VF2 in China to satisfy the growing demand for these specialty polymers in
Asia. The EUR120m plant is located built at Solvay's industrial site in Changshu in the province of Jiangsu and is scheduled to
become operational at the beginning of 2014. The TECNOFLON Fluoroelastomers family is used for demanding sealing
applications in chemical and high heat environments where high purity and long service life are essential such as those found
in the automotive, aerospace, oil and gas and energy markets. Typical end use products include O-rings, seals, gaskets and
complex molded parts. Solvay reports that demand growth for TECNOFLON is driven by the buoyant Chinese automotive
market.
Solvay is also in the process of investing some US$158m in building a new fluorinated polymers plant at its Changshu
industrial site in Jiangsu province, China. The plant is expected to start operations in 2014. The project will cater to the
electrical & electronics, wire & cable needs in the automotive market of China. Both the companies, Solvay and Rhodia, are
expected to combine their R&D facilities into one big facility Rhodia's campus in the city's Xinzhuang Industrial Zone.
In September 2012, Solvay said it would increase the capacity at its Panoli plant, India by 70 percent, for the production of
its high performance polymers KetaSpire polyetheretherketone (PEEK) and AvaSpire polyaryletherketones (PAEK). Panoli is
Solvay's largest plant worldwide for these two performance polymers that tower at the top of the plastics performance
pyramid. Nearly half of this capacity increase has already been implemented and brought on-line. The second phase of the
project will be completed by mid 2013.
In October 2012, Solvay extended its capacity for producing Solef Polyvinylidene fluoride (PVDF) at its Tavaux plant, France.
Solvay invested EUR26m (US$34m) to increase the PVDF production capacity at the plant by 50%. Solvay's Solef PVDF is,Copyright 2013, just-auto Generated on 11 April 2013 31
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TurnoverTurnoverY/e Mar 2012 Sales:JPY918,825m
Stock symbolStock symbol : 5110
Sumitomo Corporation
among others, used in separators in lithium-ion and lithium-metal-polymer (LMP) batteries in hybrid and electric cars.
In November 2012, Solvay officially opened its extended facility in Collonges-au-Mont-d'Or, France producing silica as well
as a modernised R&D facility. This investment follows a similar volume expansion in 2011 in the US and the start-up in 2010
of a new plant in China. These three investments required in total EUR74m (US$94.4m). Solvay's benchmark range Zeosil
and Zeosil Premium highly dispersible silica is used by tyre manufacturers in the production of energy-saving tyres providing
up to 30 percent reduction in rolling resistance, thereby decreasing fuel consumption by up to 7 percent, while improving
traction.
Stadco
In early 2011, Stadco acquired the former Ogihara automotive manufacturing facility in Telford, UK. The facility was
established by Ogihara Europe, part of the Ogihara Corporation, in 1994 to provide a tool making, stamping and
subassembly facility for the production of automotive parts for UK and European customers. The plant has further
strengthened Stadco’s strategy for growth with the company set to capitalise on the increase in manufacturing activity in
the UK automotive sector.
Stadco is the largest independent UK-based international supplier of automotive body-in-white products and services.
Stadco is already a key supplier in the UK for JLR.
In December 2012, Indonesian state-owned steel company PT Krakatau Steel
announced an agreement to build a new steel plant in partnership with Japan’s
Nippon Steel and Sumitomo Metal Corporation. The joint venture, to be called
Krakatau Nippon Steel Sumikin, will produce high grade flat steel mainly for the
Indonesian automotive industry which is dominated by Japanese vehicle
manufacturers. The new facility will be built in the sprawling Krakatau Industrial
Estate in Cilegon, on the eastern tip of the island of Java. Krakatau will take a 49
percent stake in the new venture with Nippon Steel & Sumitomo Metal owning the
remaining 51 percent.
In August 2012, Nippon Steel and Sumitomo and Metal One entered into a joint
venture in Mexico to build a manufacturing and sales base for automotive steel
pipes/tubes, with a view to ensuring a response to the demand for such products in
the Mexican market. The venture is scheduled to begin production in June 2013 and
will supply products to Japanese, North American and European automakers and
auto parts manufacturers in Mexico. The partners say they will continue to develop and expand their overseas businesses
actively in order to globally respond to demand for automotive steel pipes/tubes.
In January 2012, Sumitomo Electric Industries announced plans to set up an aluminium and bare copper manufacturing plant
in Thailand, reported Japan Metal Bulletin. The company has established a subsidiary with an investment of US$35m and
plans to begin operations in April 2014. The plant is expected to have a production capacity of 110 tonnes of aluminium bar
and 10,000 tonnes of bare copper wire for the fiscal 2015. This plant will provide for the demand growth of Southeast Asia
and China, specifically to meet the growing demand for magnet wire and automotive electric wiring.
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Status:Status: Public
TurnoverTurnoverYear end September 2012 sales:EUR42,326m
Stock symbolStock symbol : TKA
ThyssenKrupp AG
In May 2011, Sumitomo Pipe & Tube Co Ltd and Sumitomo Corp entered into a joint manufacturing and sales venture with
South Korea’s Hyundai Hysco Co Ltd to make automotive steel pipe in India. The venture produces pipe for a number of
applications, including stainless steel exhaust pipes, steel pipes for front forks, door impact beams and other high strength
steel pipes as a result of tighter environmental restrictions and the growing demand for safety enhancements. The plant is
located in Chennai, India.
Tenedora Nemak
In April 2012, JL French Automotive Castings entered into an agreement to be acquired by Tenedora Nemak SA de CV, a
subsidiary of ALFA. The purchase price of the transaction was not disclosed. In announcing the deal, Alvaro Fernandez Garza,
ALFA's president, said: "This acquisition offers attractive growth opportunities in aluminium transmission components.
Furthermore, JL French's technology will facilitate our entrance into other high-value added products, such as suspension and
structural parts."
ThyssenKrupp Steel Europe is investing some EUR300m in its hot strip mills in
Bochum and Duisburg, Germany. The investments will help the steel producer
strengthen its position in the premium flat-rolled carbon steel product market. Hot-
rolled strip is the basis for all ThyssenKrupp Steel Europe's flat steel products. The
company operates four hot strip mills with a total annual capacity of around 15m
metric tons.
In September 2011, ThyssenKrupp revealed that, in line with its “portfolio
optimisation," it will divest businesses for which there are “stronger alternative
strategic options.” Specifically, the board has decided to move the activities of its
Stainless Global business area to become a separate entity. Stainless Global will
then change its name to Inoxum with the new operation organised as a holding
company and with a management board performing strategic tasks and managing
the operating business units. Inoxum will bring together the worldwide production,
processing and distribution of stainless steel flat products as well as the production
and distribution of materials such as nickel alloys, titanium and zirconium. Companies with plants in Germany, Italy, Mexico,
China and the US employing around 11,300 people are organised in the Inoxum group.
Toyoda Gosei
In March 2013, Toyoda Gosei said it will create a new company in Itapetininga, Brazil, to handle production and sales of
rubber and plastic automotive components. The new company is being established to supply automotive sealing products
and safety system products, as well as interior and exterior components. The venture will be Toyoda Gosei's first production
operation in Brazil and the South American region.
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Status:Status: Public
TurnoverTurnoverFY 2012 Sales: SEK21,262m
Stock symbolStock symbol : TREL
Trelleborg AB
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TurnoverTurnoverN/a
Woodbridge Group
In April 2012, Trelleborg opened a facility in Bangalore to develop, manufacture and
supply sealing solutions for trucks and passenger cars. The facility is part of
Trelleborg’s Sealing Solutions business.
In March 2012, Trelleborg announced that it has completed divestment of its France-
based operation that manufactures high-technology rubber, plastic and foam
components and systems for the light vehicles industry. The buyer is Bavaria
Industriekapital with its registered office in Munich, Germany.
In January 2012, Trelleborg sold an operation that manufactures high-technology
rubber, plastic and foam components and systems for the light vehicle industry. The
operation is primarily located in France and is part of the supplier's automotive
business area. The buyer is Bavaria Industriekapital of Munich. The operation makes
components for pedal boxes and bump stops for all opening panels such as the boot
lid, doors and bonnet. The operation also supplies other components such as gaskets
and moulded hoses offered in a range of polymer materials. The operation is a separate unit in Trelleborg Automotive and is
not connected to the antivibration business for light and heavy vehicles, which will be included in a joint venture with
Freudenberg.
In June 2012, Woodbridge Group announced the development of a flame retardant
foam for a range of under hood acoustical and thermal insulating applications. Its so-
called WhisperTech V0 foams are used in the engine bay, specifically bonnet (hood)
liners as well as dash insulators.
In August 2011, Woodbridge Group entered into a new joint venture with the
Summa Group to produce moulded plastics for automotive applications. Production
is underway at a facility in Leon, Mexico, alongside the partners’ existing joint
venture plant. The venture, known as DuraLite Formed Plastics, produces
polypropylene (EPP) and expanded polystyrene (EPS) capabilities. Automotive
products manufactured at this facility include cargo management components,
seating frames, NVH acoustical management components and crash force
management components, such as head and side impact countermeasures and
bumpers.
In December 2010, the Woodbridge Group and Toscana Gomma signed a technical agreement to develop polyurethane
technology and chemistry for integral skin solutions. Toscana Gomma is a subsidiary of the Italian Olmo Group and produces
slab and molded flexible polyurethane foams. Toscana Gomma is a supplier to original equipment manufacturers, and Tier 1
automotive system suppliers. The company also supplies technical foams for a range of applications. The Woodbridge Group
develops and produces polyurethane and expanded polypropylene products. Its automotive applications include components
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for seating, structural support, interior soft trim products, headliner systems, cargo management solutions, and engineered
products for occupant protection and acoustical management.
Materials
According to VCD Verkehrsclub Deutschland, reducing the weight of a vehicle by 100 kilograms lowers fuel consumption by
0.5 litres over a distance of 100 kilometres and cuts carbon dioxide emissions by 1.2 kilograms over the same distance.
Lightweight structures are now more important than ever given the trend toward future-oriented drive technologies such as
electric mobility.
Although the car is built from many different materials, its main structure – known as the body in white (BIW) – is usually
made of steel pressings welded together to form a strong and stiff frame. According to Corus, this method of construction
accounts for 99.9% of all cars produced in the world. The remaining 0.1% are mostly constructed with an aluminium BIW,
while a very small number (fewer than 0.01%) are constructed from carbon fibre composite. The BIW of a vehicle accounts
for 20% of the vehicle mass, says Corus. The weight of the closures (doors, bonnet and boot/rear hatch), chassis (suspension
parts) and driveline bring the total amount of steel and other ferrous metals to more than 60%.
Corus reports that, in recent years, the amount of ferrous metal has declined, mostly driven by manufacturers replacing iron
with aluminium for engine castings. The percentage of sheet steel per car has also dropped, mainly due to:
higher levels of equipment, trim and sound-proofing;
more aluminium used in wheels and suspension parts;
more moulded plastics, especially under the bonnet.
The environmental and economic requirements for reduced fuel consumption have also led to an increase in the use of
lightweight materials for components that bolt on to a conventional steel vehicle, but at a cost. The following table
indicates the potential weight savings of using alternative materials to steel and the additional cost involved.
Alternative materials: potential weight saving versus costAlternative materials: potential weight saving versus cost
Source(s)Source(s) Corus Automotive Book of Steel
Steel
(kg) Aluminium
(kg) Magnesium
(kg)
% weightreduction(part)
% weight reduction(vehicle)
% costincrease(part)
Body inwhite 285 218 n/a 23.5 3.901 250
Bonnet(assembly) 14.8 8.3 n/a 44 0.482 300
Door(assembly) 15.7 9.5 n/a 39 0.403 275
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NotesNotes "1. Example vehicle mass of 17,00kg
Alternative-materials-potential-weight-s_13612760152393.csv
According to the European Aluminium Association, every 100kg of weight saved equates to lower emissions of nine grams of
CO2 per kilometre and 0.35 litres of fuel per 100 kilometres.
According to Bosch, a vehicle’s unitised body consists of sheet-metal panels, hollow tubular member and body panels that
are joined together by multi-spot welding machines or welding robots. Individual components may also be bonded, riveted
or laser-welded. Depending on the vehicle type, says Bosch, roughly 5,000 spot welds must be made along a total flange
length of 1.2-2.0 metres. The flange widths are 10-18mm. Other parts, such as front bumpers, doors, bonnet and boot lid,
are bolted to the body supporting structure. Other types of body construction include frame and sandwich designs.
BASF designfabrik is offering a new tool to designers and development engineers working in automotive design. Its so-called
Material Kit displays a large proportion of BASF's know-how in materials: Organised on the basis of feel, appearance and
function, the Material Kit presents 30 different BASF products in the form of 4 x 6 cm samples that can be touched and felt.
As a result, designers can get a real feel for the BASF products they are considering for their automobile interior design
concepts. The materials can be examined, touched and compared, be they satin- or leather-like finishes, rigid or flexible
polyurethane surfaces, foams, coatings, pigments, ceramic powders for injection molding or high-performance thermoplastic
resins.
Since 2006, the European directive End of Life of Vehicle (ELV) requires that 85% of all material in new vehicles models
must be recoverable. The level will be raised to 95% by 2015. Although the directive on ELV only specifies recovery levels
for whole vehicle and not for individual components, most manufacturers are working toward ensuring their products meet
or exceed the legal requirements.
Aluminium
Overview
Aluminium is being used in a variety of vehicle manufacture applications, including body panels and wheels. In addition,
some vehicle makers are switching from traditional iron blocks for engines to aluminium construction. Although not as
durable as iron, aluminium is lighter thereby boosting fuel economy.
Today, aluminium competes with other materials, such as steel, plastics, composites, and glass, amongst others, for various
applications in certain automotive markets. The automotive market is one of the largest and fastest-growing market sectors
for aluminium producers.
Where aluminium products compete with other materials – such as steel and plastics for automotive and building
applications; magnesium, titanium, composites and plastics for aerospace and defence applications; steel, plastics and glass
for packaging applications – aluminium’s diverse characteristics, particularly its light weight, recyclability and flexibility are
also significant factors.
In a paper presented at an IQPC conference on door systems, Dura Automotive Systems referred to the move from usingCopyright 2013, just-auto Generated on 11 April 2013 36
steel to aluminium, highlighting the advantages and disadvantages, adding: “Aluminium structural assemblies carry a price
premium due to relatively high sub-component and production costs when compared with conventional steel construction,
but offer weight reduction of typically around 20kg per car (depending upon geometry). Aluminium structural assemblies
offer greater design efficiency, through feature integration and strength optimisation, whilst at the same time requiring less
design compromise in terms of shape and package space. Cost per kilogram weight saving (EUR/kg) for aluminium structural
assemblies is a simple figure to calculate but a difficult figure to evaluate.”
According to Alcoa, the increasingly restrictive fuel efficiency laws that are compelling automakers to lighten the vehicles'
weight are set to make aluminium the preferred alternative, thus increasing its demand two-fold by 2025. Automakers are
moving away from steel and are seeking aluminium alternatives to make components, said Alcoa's director of automotive
marketing, Randall Scheps, Reuters reported in June 2012. He said: "We have every car maker calling us, wanting to increase
their aluminium content, wanting to start new R&D projects about how they can convert bodies from steel to aluminium,
wanting to convert hoods and doors from steel to aluminium." The auto industry consumed around 11.5 million tons of
aluminium in 2011 which is set to increase to an estimated 24.8 million tons by 2025. An average car will use 250 kilograms
of aluminium by 2025 as compared to 155 kilograms being used in 2012.
Applications
Introduction
According to the European Aluminium Association, there are a number of applications for greater use of aluminium in
vehicle manufacture. These include:
Air compressor pistons
Body structure and components
Brake components
Bumper systems
Driveshafts
Electrical distribution systems
Engine blocks
Engine sub-frames
Exterior closure panels
Heat exchangers
Instrument panel structures
Copyright 2013, just-auto Generated on 11 April 2013 37
Seat frames
Suspension components
Suspension sub-frames
Wheels
Windshield surround structures
This section highlights some notable advances in some of these applications.
Constellium’s aluminium crash management system
Mercedes-Benz is sourcing Constellium’s aluminium Crash Management System for its C-Class vehicle. The system features
crash boxes inserted in the front structure of the car for improved safety.
Audi Space Frame
Bosch points out that, since 1994, an aluminium body has been in use on one of the German luxury sedans. The vehicle’s
frame is constructed from aluminium extruded sections, and the panel parts are integrated as self-supporting parts (ASF or
Audi Space Frame). The implementation of this principle, says Bosch, required the use of suitable aluminium alloys, as well
as new production processes and special repair facilities.
Novelis supplying aluminium sheet to GeneralMotors
Novelis Inc is supplying aluminium sheet for the bonnet and liftgates of the Chevrolet Tahoe Hybrid and GMC Yukon Hybrid
SUVs. Novelis says the body of the hybrid vehicles is approximately 400lbs lighter than a standard model, achieved in part
through significant application of aluminium. The use of aluminium helped GM to offset the weight of the hybrid drive,
battery pack and related hybrid hardware. GM already sources Novelis’ aluminium sheet material for its GMC Acadia, Buick
Enclave, Cadillac CTS and Buick Lucerne models.
Heat shield from Federal-Mogul
Federal-Mogul has developed a lightweight heat shield material called Nimbus GII. The company claims that it provides
both high thermal efficiency and formability for creating complex shapes for custom applications. Nimbus GII also is up to
approximately 80 percent lighter than typical steel sandwich heat shields, says Federal-Mogul’s engineers. The heat shield’s
construction consists of two thin corrugated aluminium sheets, providing a rigid structure. An insulating air pocket between
the two layers increases the inherent high thermal performance of the aluminium. The net result, says Federal-Mogul is aCopyright 2013, just-auto Generated on 11 April 2013 38
15-30 percent improvement in thermal protection when compared to a typical sandwich-style heat shield construction.
Nimbus GII heat shields are in production for automakers at Federal-Mogul’s manufacturing facilities in Skokie, Illinois; Port
Elizabeth, South Africa; Tepotzilan, Mexico and Nanchang, China.
JLR's increasing use of aluminium
According to Tata, the Jaguar XJ’s aluminium structure makes it 300 pounds lighter than a body shell made from steel. Tata
claims that at between 3,800 and 4,300 pounds (depending on the specific model), the XJ is lighter even than the steel-
bodied XF. Compared to its main rivals - the BMW 7 series and Mercedes S-class - the XJ is between 300 and 570 pounds
lighter.
Furthermore, the current Range Rover incorporates an integrated steel monocoque body, using steel sub-frames with
aluminium doors, front fenders, and bonnet. By switching to the aluminium body shell would pare between 700 and 900
pounds from the vehicle’s current weight. Removing up to 900 pounds from the bodyweight would increase fuel economy by
an estimated 15 percent—from 19 mpg highway to 22 mpg.
2013 Cadillac ATS
The 2013 Cadillac ATS uses advanced materials to minimise weight throughout the compact luxury sports sedan. The
carmaker claims that lightweight parts such as an aluminium hood and magnesium engine mounts help ATS achieve a curb
weight less than 3,400 pounds, and highway fuel economy well over 30 mpg. The main features include:
Using cast iron in the rear differential instead of aluminium;
In the rear suspension by using specially engineered straight steel links with lightening holes instead of using
aluminium; and
An acoustically laminated windshield and side windows that are lighter than standard tempered glass and provide
better wind and powertrain noise reduction for a quieter interior.
2013 Tesla Model S
The Tesla Model S sedan has been hailed by the US Aluminium Association's Aluminium Transportation Group (ATG), for its
intensive use of the material to help the all-electric vehicle save weight.
"Tesla's Model S is an example of the next frontier in what automakers are achieving with aluminium," said ATG chairman
Randall Scheps. "Tesla is among the leaders driving automotive aluminium use, which will double within a decade yielding
more mass- produced, high-volume aluminium-intensive vehicles that will hit showrooms.”
The Association claims aluminium use in electric and other alternative powertrain vehicles helps offset heavy battery
weight, increasing driving range or fuel economy and improving performance.
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Aluminium sheet from Kobe Steel
Kobe Steel is marketing an aluminium sheet that offers good heat-dissipating qualities. The sheet can be used for
maintaining the high performance of electronic devices, protecting devices such as computer-controlled boxes and car
navigation systems.
Engine cooling
Kustom Cooling Products is offering an aluminium radiator and air conditioner condenser line for trucks. The company claims
these products are 100% aluminium including the core, side supports and tanks. The core features a wavy style fin built in a
bar and plate configuration. Aluminium allows much higher operating temperatures and since the tubes themselves are
thicker than OE, it allows for better thermal stress, vibration and shock absorption.
GM's aluminium welding technology
General Motors Research and Development has invented an industry-first aluminium welding technology expected to
enable more use of the lightweight metal on future vehicles, which can help improve fuel economy and driving performance.
GM's new resistance spot welding process uses a patented multi-ring domed electrode that does what smooth electrodes
are unreliable at doing - welding aluminium to aluminium. By using this process GM expects to eliminate nearly two pounds
of rivets from aluminium body parts such as hoods, liftgates and doors.
GM already uses this process on the hood of the Cadillac CTS-V and the liftgate of the hybrid versions of Chevrolet Tahoe
and GMC Yukon. Historically, automakers have used self-piercing rivets to join aluminium body parts, because of variability
in production with conventional resistance spot welding. However, rivets add cost and riveting guns have a limited range of
joint configurations. In addition, end-of-life recycling of aluminium parts containing rivets is more complex.
Honda's steel-aluminium jointing solution
Honda has developed a technology to join steel and aluminium that will enable the use of aluminium rather than steel outer
door panels to reduce vehicle weight. Using the technology, the combined weight of the four door panels of the new Acura
RLX luxury sedan, headed for US showrooms next month, has been reduced by 11kg, or 17%, helping to improve fuel
economy, Honda told Kyodo News. As for models sold in Japan, the new '3D lock seam' technology will first be applied to
the next Legend luxury sedan to be released in 2014, Honda said.
PSA Peugeot Citroen looks for aluminium partners
In September 2011, PSA Peugeot Citroen chairman Philippe Varin told the Metal Bulletin aluminium conference in Paris, that
the automaker would consider "a mutually beneficial partnership" with aluminium suppliers.
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"The larger use of aluminium in our cars can only be achieved if we manage to build global and mutually beneficial
partnerships," he said."The price difference we have today between steel and aluminium can only be overcome by a better
approach of value."
Varin told the conference that Peugeot is "definitely considering entering into strategic supply relationships with some
commodity suppliers," adding that the group is also looking at plastics and composites to help save weight.
Peugeot had already developed global partnerships with car parts suppliers but did not have such ties with raw material
suppliers, he said.
After the average weight of its cars rose to 1,250kg from 800kg 35 years ago, Peugeot wanted to reverse the trend by
eliminating 100kg in each of its next two generations of models, he said.
Greater use of aluminium, which currently represents about 100kg in the overall weight of its cars, would allow Peugeot cut
its vehicle weight by 150kg, he said but cautioned that using aluminium also involved substantial investments in adapting
production lines.
Carbon fibre
Overview
Increasingly, strict global environmental standards and fuel economy regulations have intensified the need to reduce vehicle
mass by using lightweight materials in place of high-tension steel or aluminium.
Carbon fibre reinforced plastics have been drawing industry attention as their lightness and strength can help the fuel
efficiency of vehicles, but the time-consuming work required to produce the materials is a drawback.
Carbon fibre reinforced polymer or carbon fibre reinforced plastic is a strong, light and expensive composite material or
fibre-reinforced polymer. For some time, it has been used in a number of applications for aerospace and marine fields.
Carbon fibre is now making its way into vehicle manufacture.
Since carbon fibre is stronger, tougher and lighter than steel, it can help increase fuel efficiency due to its lighter weight.
Indeed, as carbon fibre is ten times stronger than regular-grade steel yet only one-quarter of the weight, carbon fibre
composites used as automotive components are expected to reduce vehicle weight. Consumers benefit from lighter weight
vehicles with better fuel economy and all the safety benefits that come with vehicles of greater mass.
Ford carbon f ibre bonnetFord carbon f ibre bonnet
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Applications
Armoured vehicles
Demand for armoured vehicles is growing because of increased criminality, wars and the fact that certain people are fearful
for their safety. According to the consultancy, dpa, the more serious the security situation, the more demand there is for
armoured vehicles, which carry high levels of profit for companies.
BMW adapts its 5-series and X5 for an add-on price of EUR49,000. This involves dismantling cars and rebuilding them with
the addition of more than 200 steel plates, as well as carbon fibre panels and special glass. Audi and Mercedes also offer
high security versions of the A6 and E-Class respectively.
BMW to use carbon fibre in its i3 electric vehicle
BMW is using carbon fibre reinforced plastic (CFRP) in its i3 electric vehicle. The carmaker estimates this will save around
300kg in weight following the start of production in 2013. BMW says the use of carbon fibre was a "small revolution" in
vehicle production. "The i3 will be the first volume production car [whose] body is made up of CFRP," said BMW
development board member Klaus Draeger. "This is a small revolution in car manufacturing - this brings advantages because
of the life drive technology and because of carbon we will offset the weight of the battery almost completely - we can save
about 300kg."
In March 2013, BMW said it has already received "several hundred" advance orders for its i3 electric car due to be launched
in late 2013.
Bentley's Continental Supersports model
Bentley’s Continental Supersports model is equipped with lightweight sports seats with carbon fibre clamshell rear panels. In
the rear compartment, the seats are replaced by a stowage deck with a carbon fibre luggage-retaining beam. Leather trim is
standard but carbon fibre panels replace traditional wood veneers.
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Carbon ceramic disc brakes
Carbon ceramic disc brakes are being studied and applied, albeit in niche applications. “Carbon ceramic discs will find their
way into high-end car applications today and in the future,” said Guenther Plapp, executive vice president, engineering of
Bosch’s Chassis Systems Brakes division in an exclusive interview with just-auto. “Since the manufacturing processes are
rather complex, they will remain a special niche product for sports applications with high appeal and image potential. Good
handling due to low weight is another attribute which sporty drivers will appreciate.” Bill VanderRoest, technical director,
Foundation Brakes, TRW Automotive, told us: “There have been some interesting developments in advanced materials such
as carbon fibre discs which provide advantages under extreme braking conditions. Because of their cost premium, the
application of such materials is limited to the very high-end performance vehicles.”
Meanwhile, IFR Automotive has developed and patented its Twin Brake Disc (TBD) system. As the name implies the
lightweight stainless steel brake system comprises twin discs, each with turbine shaped slots for maximum air cooling and
braking efficiency. To find out more, Matthew Beecham talked with Ignacio Fernandez of IFR Automotive about the ways in
which carbon-ceramic brakes advanced over the past few years? He told us: “We have been testing some carbon-ceramic
brakes on the latest high-performance cars and the major problem is still there; you have to warm up the brakes before you
get the right friction between the pad and discs every time you are going to brake. To me this characteristic of carbon-
ceramic brakes is totally unacceptable. At IFR, we are convinced that a steel twin-disk brake system, such as TBD, provides
superior performance with better cost-efficiency.”
Carbon fibre body panels for hybrid and electric cars
A team of engineers at Volvo is part of a three-year consortium project, led by Imperial College, London, looking at how a
carbon fibre composite that can store more energy than conventional batteries could be used to make body panels of hybrid
gasoline/electric vehicles, making them lighter and more energy efficient, and enabling them to travel longer distances
before needing to recharge.
The partners involved in the €3.4m EU-funded project are developing a composite of carbon fibres and polymer resin that
will store and discharge large amounts of energy much quicker than conventional batteries.In addition, the composite
material does not use chemical processes, making it quicker to recharge than conventional batteries.
The researchers say that the recharging process causes little degradation in the composite material, whereas conventional
batteries degrade over time. The composite material could be charged by plugging a hybrid car into a household power
supply.
The project is also exploring other alternatives for charging it, such as recycling the energy created when the car brakes.
Carbon fibre reinforced plastics
Japanese textile maker Toray Industries and Daimler are working together to make and sell vehicle parts using carbon fibre
reinforced plastics. The venture began by supplying carbon fibre components for Daimler's Mercedes-Benz passenger
vehicles launched in 2012. The company is headquartered in Esslingen, Germany and capitalised at EUR825,000, with TorayCopyright 2013, just-auto Generated on 11 April 2013 43
holding a majority stake of 50.1 percent and Daimler 44.9 percent. The remaining 5 percent is held by other investors.
Nissan’s SpecV version of its GT-R ‘halo car’
Nissan’s SpecV version of its GT-R ‘halo car’, introduced in February 2009 in limited numbers in Japan, features include
carbon fibre rear spoiler, grille and brake ducts. Inside, it has only two seats which are special Recaro carbon fibre units.
Carbon fibre insets trim the rear centre storage box, instrument panel and other areas.
Seating
JCI is developing a concept with industry partners that will reduce vehicle weight and improve fuel economy. The project,
called CAMISMA (Carbon fibre- / Amid- /Metallic structural interior component using a multi-material approach), is
supported by the German Federal Ministry of Education and Research. The project team are exploring the use of fibre-
reinforced composites (FRC), particularly those based on carbon fibre to replace steel. JCI’s partners include Evonik
Industries, Jacob Plastics, Toho Tenax Europe and the Technical University Aachen.
An automotive seat is being developed, manufactured and tested, as a concept for the approach used by the project team.
The objective is to achieve a 40 percent weight reduction compared to conventional metal-based designs. JCI has a
production-ready version of a rear seat backframe that incorporates adhesive bonded steel and aluminium components.
Carbon fibre roof for Ferrari Superamerica 45
The Ferrari Superamerica 45 incorporates elements of the SA APERTA, an open-top version of the current 599 - and the
575M Superamerica. Similar to the 575M Superamerica originally unveiled in 2003, the Ferrari Superamerica 45 features a
rotating one-piece roof section. It is made of carbon fibre (instead of the earlier car’s glass), incorporates a rear screen and
swivels to retract under a carbon fibre boot.
Daimler invests in carbon fibre
Daimler is investing in the use of lighter materials such as carbon fibre in the development and production of motor vehicles.
For example, the SLS AMG E-CELL body shell shown by Mercedes-Benz AMG at the 2011 Frankfurt motor show is part of the
carmaker’s so-called AMG Lightweight Performance. "AMG Lightweight Performance is the term we use at AMG to
encompass all the different technologies involved in lightweight construction,” said Tobias Moers, member of the board of
management of Mercedes-AMG GmbH, responsible for overall vehicle development. “The use of carbon makes vehicles not
only lighter, but even more efficient and agile - in motorsports and on the streets. This is especially important for sports
cars."
The carbon-fibre battery monocoque in the SLS AMG E-CELL forms an integral part of the body shell. The carmaker points
out the advantages of carbon composite materials, including their high strength which makes it possible to create rigid
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structures in terms of torsion and bending, good crash performance and low weight.
Ford invests in carbon fibre
Cutting the weight of new cars and trucks by up to 750 pounds by the end of the decade is a key component of Ford's
strategy to improve fuel efficiency. In order to help achieve that goal, the carmaker is partnering with Dow Automotive
Systems to research the use of advanced carbon fibre composites in high-volume vehicles.
Paul Mascarenas, Ford chief technical officer and vice president, Research and Innovation said, "There are two ways to
reduce energy use in vehicles: improving the conversion efficiency of fuels to motion and reducing the amount of work that
powertrains need to do. Ford is tackling the conversion problem primarily through downsizing engines with EcoBoost and
electrification while mass reduction and improved aerodynamics are keys to reducing the workload."
Ford is investigating a range of new materials, enhanced design processes and new manufacturing techniques that would
enable automotive structures to meet increasingly stringent safety and quality standards while cutting weight.
If the joint development effort is successful, carbon fibre components may begin appearing on new Ford vehicles in the latter
part of this decade as product development teams' work toward meeting new fuel efficiency standards of more than 50 mpg
and extending the range of plug-in vehicles.
GM invests in carbon fibre
Engineers from GM and Teijin Ltd are working together to develop advanced carbon fibre composite technologies for
potential high-volume use globally in GM cars, trucks and crossovers. The co-development pact involves use of Teijin's
carbon fibre reinforced thermoplastic (CFRTP) technology, a faster and more efficient way to produce carbon fibre
composites that potentially could be introduced on mainstream vehicles.
JCI's solution
Johnson Controls has applied its expertise in natural fibre processing technology to carbon fibre exterior body parts. The new
process is based on a wet press process which JCI has used since 2003 to produce wood fibre components for vehicle
interiors. In the newly adapted process, a carbon fibre mat pre-moistened with resin is placed between the forming tools and
then pressed. During the pressing cycle, the excess resin leaks onto the edge of the mould. This provides a very high fibre
density in the body parts.
Coatings
OverviewCopyright 2013, just-auto Generated on 11 April 2013 45
There are three markets for automotive coatings:
1. Coatings applied to vehicle bodiesCoatings applied to vehicle bodies – following pre-treatment of the vehicle body to remove grease, oils and dust,
four generic types of finish are typically applied, i.e. electrocoat, primer-surfacer, basecoat (or colourcoat) and
clearcoat.
2. Coatings used to coat automotive plastic componentsCoatings used to coat automotive plastic components – there are certain differences between products used
to coat plastic components and those supplied for coating vehicle bodies. In particular, a coating product such as
electrocoat is not used to coat plastic components
3. Coatings for aftermarket applicationsCoatings for aftermarket applications – the principal aftermarket customers are independent bodyshops
(accounting for 55 percent of aftermarket sales to motorists) and vehicle maker franchisees. Coating products supplied
for the OE and aftermarket constitute different relevant product markets. Six principal products are supplied to the
aftermarket: primer, basecoat, clearcoat, thinners, activators and putty.
Colour trends
Times have truly changed since Henry Ford offered his black-only Model T in 1909. DuPont pioneered the first fast-drying
lacquer paint in 1923, giving consumers their first colour options beyond black for mass-produced vehicles. Paint
manufacturers, such as BASF Coatings, PPG Industries and DuPont, typically offer some 150 new colour shades each year.
Today, the vehicle exterior is a vitally important element in the brand differentiation of vehicle makers and a kind of
business card for its owner. Although people spend huge sums of money on their cars, wanting to see and be seen from
inside them, their choice of colour for the bodywork is still conservative. Subdued colours appear to be the order of the day
across the globe. Shades of silver, grey and blue are the preferred choice, worldwide.
However, not so long ago, there were clear national differences influenced by racing team colours. The British racing team
opted for green, the Germans silver, blue for the French while the Italians opted for Ferrari red. The Japanese, meanwhile,
chose white.
DuPont's research
According to research by Ford and DuPont, grey and silver are most popular vehicle colour choices in New York and Los
Angeles. Meanwhile, San Franciscans like white and Bostonians like black. Only one country in Europe has a top
colour other than white, black or silver: The Czech Republic chooses blue, says Ford.
"The trend continues to be toward core colours - the classics," said Susan Swek, Ford's group chief designer for Colour and
Materials. "We strive within Ford to achieve the best black, silver, white and gray. We're always working to make them even
more appealing."
Paint, she said, is no different from clothing when it comes to colour and style. "The classics are continually upgraded - and
always with a modern twist," Swek said. "In Europe, we've added tri-coat pearl technology to give gray-scale colours a
glimmer. And in North America we are creating more tinted clear coats for a rich, luscious effect."
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A new core colour, Silver Diamond PC (for premium colourant), takes silver to a whole new dimension with an "elegant,
liquidy look," explained colour designer Jon Hall.
"We're generally paying more attention to fundamental colours," Hall said. "They are 60 percent of the global market. Cars
and trucks are a major purchase, and customers think of things like resale value and the fact that they want to be seen in
the vehicle for the next few years."
Across the Atlantic, tastes tend to be equally as diverse: French and Italian motorists like cream-coloured vehicles, not a
surprise given their cafe cultures. The Irish like silver. Customers in Denmark prefer black, while those in Belgium like grey.
Vehicle owners everywhere use colour choice to convey messages about themselves, says Julie Francis, of the European
Colour and Materials team.
"There is something very personal to buyers about the colour of their cars," said Francis. "When you look at the culture, you
can see how fashion and other tastes influence the colours customers choose."
Nearly 50 percent of all vehicles sold in Turkey are white. Black is the colour of choice for most drivers in Norway, Portugal,
Germany and Russia. And, besides Ireland, Romania, Finland, Poland and Sweden chose silver more times than not.
"Red used to be, far and away, the most popular colour," said Vince Show, marketing and product strategy manager for Ford
of Europe. "White is in the ascendancy now. Dark greys, blacks and blues are popular, as they are in men or women's
clothing."
"It's important to get the right colour into the market at the right time," Swek said. "Too early, and it won't have registered
on customers' radar. Too late, and the popularity of a particular colour may have already reached its peak."
These findings are from Ford's annual look at US car buying preferences as well as an international colour study by DuPont.
PPG's research
PPG Industries has released the results of its coating survey. Black ranked as the most popular vehicle colour in Europe and
white ranked as the most popular vehicle colour in the world.
More specifically, in Europe, black is the most popular colour (26 percent), followed by white (19 percent), silver (16
percent), grey (15 percent), blue (9 percent), red (7 percent), naturals (5 percent), green (2 percent) and other/niche colours
(1 percent). Globally, approximately 21 percent of 2011 model-year cars around the world have been white, and silver and
black tied for second most popular at 20 percent.
In North America, white was first (20 percent), followed by silver (19 percent), black (18 percent) and grey (15 percent). Red
and blue were tied for fifth (9 percent), followed by naturals such as browns, tans, golds, oranges and yellows (7 percent),
green (2 percent), and other/niche colours (1 percent).
In the Asia/Pacific region, silver is the most popular colour (25 percent), followed by white (23 percent), black (17 percent),
grey (8 percent), red (10 percent), blue (7 percent), naturals (7 percent), green (2 percent) and other/niche colours (1
percent).
"Colour is one of the most basic means of human expression," said Jane Harrington, PPG manager, colour styling,
automotive coatings, based at the company's automotive technology centre in Troy, Michigan, US. "The palette of coloursCopyright 2013, just-auto Generated on 11 April 2013 47
[205]
being developed for the automotive segment is being influenced by culture, nature, fashion, interior design, media, auto
shows, colour popularity and new pigment technology."
Other
Federal-Mogul Federal-Mogul has developed a new piston ring coating that supports vehicle manufacturers’ efforts to make gasoline
engines more fuel-efficient. The company claims that its so-called CarboGlide reduces ring friction by up to 20 percent as
compared to nitride or other commonly used coatings. CarboGlide’s coating properties are achieved due to a multi-layer
microstructure and a special coating composition that contains carbon, deposited in diamond-like form, as well as hydrogen
and tungsten. The structure can be produced for a coating thickness of 10 microns, more than three times that of the
industry’s latest DLC coating.
BASFBASF has developed an automotive clearcoat that provides the car with a glossy appearance for significantly longer than
conventional coatings. Previous standard clearcoats for cars have consisted almost exclusively of organic material, referred
to as polymers, which are long-chain branched hydrocarbons. In contrast, BASF’s so-called iGloss combines two kinds of
materials in a nanostructured hybrid. Between 90 and 95% of the hybrid material, depending on the area of application,
consists of organic material which forms the paint matrix. This makes the finish flexible and elastic and ensures a high level
of weathering resistance. The special nanostructure of the coating does not form until the paint, with the addition of a
hardener together with a catalyst, is baked on the surface of the car at a temperature of around 140 degrees Celsius. If
needed, the lattice structure can also be formed at lower temperatures if the right catalyst system is selected. It has been
used in mass production since mid-2011.
Mat surfaces have been adding a special touch to cars for a number of years. BASF’s Glasurit has developed a new clear
coat system for the refinish repair and can now offer an enlarged range of gloss levels.
In January 2013, the commercial coatings group of PPG Industries'PPG Industries' automotive refinish business introduced ALK28-901, a
factory-packaged 2.8 VOC (volatile organic compound) alkyd enamel intended for general industrial use. The new black
topcoat is claimed to be fast-drying and suitable for trailers, metal fabrications, castings, cabinets, machinery and heavy
equipment.
In March 2013, Bayer MaterialScienceBayer MaterialScience revealed it has developed a new polyacrylate binder that can be used to
formulate topcoats with a very low concentration of volatile organic compounds (VOC) for large vehicles as well as farming
and construction machinery. In the case of commercial vehicles, buses, farm machinery and trains, coatings usually are
cured at temperatures of between 60 and 80°C, levels that are significantly lower than in passenger car production lines, for
instance. This frequently is the most cost-effective method in view of the low unit volumes and large size of the vehicles.
The supplier points out that coatings can be produced with the new polyacrylate binder that is optimally adapted to these
conditions. In addition, because closed coating systems with solvent recovery or afterburning are not as common for painting
large vehicles as they are in the passenger car industry, paints with a low VOC content are all the more important.
Magnesium
OverviewCopyright 2013, just-auto Generated on 11 April 2013 48
[206]
Magnesium is the lightest structural metal. It weighs around a quarter as much a steel and is 35 percent lighter than
aluminium. Parts made from magnesium are particularly attractive for automotive OEMs as their lower weight allows
reductions in vehicle CO2 emissions. In the past, however, the material has only been used in the form of castings, for
example in the chassis or in transmission housings and engine blocks. For large body parts, where the light material could
save a lot more weight, affordable magnesium sheets are required.
As part of the InCar project for automotive innovations, ThyssenKrupp recently demonstrated that a car roof made of
magnesium is 62 percent lighter than a current conventional steel solution. Related to the part, says ThyssenKrupp, CO2
emissions during driving would be reduced by more than half.
In addition to vehicle manufacture, magnesium sheet can also be used in engineering and other areas of industry where
weight reduction is important.
In November 2010, Freiberg University of Mining and Technology and MgF Magnesium Flachprodukte GmbH inaugurated a
new hot rolling mill for magnesium. The EUR7.5m funded by the state of Saxony, is operated by the university’s Institute of
Metal Forming. It extends aproduction line for magnesium flat products developed jointly by the university and MgF. MgF is
a subsidiary of ThyssenKrupp Steel Europe AG. For ThyssenKrupp Steel Europe, the magnesium activities add to the range of
intelligent lightweighting materials the company produces for areas such as the auto industry. MgF and the Institute of
Metal Forming at TU Bergakademie Freiberg jointly developed a concept for the production of magnesium sheet using a
casting-rolling line to manufacture flat strip directly from molten magnesium.
South Korean steelmaker POSCO and Magnesium Flachprodukte GmbH (MgF), a subsidiary of ThyssenKrupp Steel Europe
AG, are working together to produce magnesium sheet. In October 2010, the two signed a memorandum of understanding
to support each other in the event of supply bottlenecks. Automotive OEMs are the most important customers for
magnesium sheet. POSCO and MgF both produce magnesium sheets on casting-rolling mills, POSCO’s near Gwangyang in
South Korea, and MgF’s in Freiberg in the German state of Saxony. At both companies, this strategy reduces the cost of
producing magnesium sheets. They claim that casting-rolling technology uses lower-cost input materials and greatly
reduces the number of production steps compared with conventional magnesium sheet production.
In October 2012, GM said it is testing an industry-first thermal-forming process and proprietary corrosion resistance
treatment for lightweight magnesium sheet metal that will allow increased use of the high-strength alternative to steel and
aluminium. GM wants to expand its use of low-mass parts on vehicles around the world and will pursue licencing
opportunities related to this breakthrough technology. The goal is for suppliers to be able to use the process to provide
significant amounts of magnesium sheet that will trim pounds from vehicle mass. The use of magnesium, which weighs 33%
less than aluminium, 60% less than titanium, and 75% less than steel, will help customers save money at the gas pump, as
will more efficient conventional engines and electric powertrains.
Applications
Seating
Magna has developed an injection-moulded magnesium seat structure. During an interview with Imtiyaz Syed, vice
Copyright 2013, just-auto Generated on 11 April 2013 49
president, engineering, Magna Seating, , Matthew Beecham asked about this seat structure i.e. the materials and moulding
technology used, the benefits and the ways in which this system meets your customer needs. He told us: “Moulded
magnesium starts out as the same raw material as for die casting. The difference is in the moulding process which is
essentially like plastic injection moulding of semi-solid magnesium. The results are much higher ductility, higher strength,
better dimensional stability and fewer post-forming operations like machining and assembly. It’s a process that is in
automotive production on components like convertible roof mechanisms, mirror mounts and power liftgate transmission
housings; seating is a great application due to the mass-save potential. We’re seeing the industry becoming gun-shy with
magnesium though, due to the volatility in global raw material pricing.”
Organic materials
Overview
The use of organic materials in cars is not new. For some time, component suppliers and automakers have focused on
promoting environmentally friendly technologies in all product segments. In the area of seating, for example, coconut fibre
seat pads have been used in order to meet manufacturers' economic and ecological objectives while contributing to
sustainability. For example, Mercedes-Benz uses coconut matting, crushed olive stones and even sawdust in certain
vehicles.
Applications
Acoustical foam
Using a grant from the United Soybean Board, Dow Automotive Systems has developed a soy-oil containing acoustical foam
formulation. Developed under the trade name Betafoam Renue, the new formulation can be injected into vehicle cavities
like A, B, C pillars and rocker panels to reduce air and road noise. It replaces baffles traditionally used in these areas and is
also low density to reduce overall vehicle weight.
Doors
Ford is using kenaf, a tropical plant related to cotton and okra plants, to replace oil-based materials in the doors of the Ford
Escape. The automaker claims that use of this material is anticipated to offset 300,000 pounds of oil-based resin annually
in North America and that kenaf reduces the weight of the door bolsters by 25 percent. Kenaf is a tropical plant that Ford
describes as looking similar to bamboo and is related to cotton. Kenaf oil is used in cosmetics and kenaf fibre is used as an
alternative to wood in the production of paper. The upper leaves and shoots of the plant are edible. The kenaf is combined
with polypropylene in a 50-50 mixture inside the door of the Escape. International Automotive Components (IAC)
manufactures the door bolsters in Greencastle, Indiana, US.
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Engine parts
Toyota Boshoku has developed engine parts using kenaf fibre in order to reduce carbon dioxide emissions and reduce the
weight of vehicles. Forty percent of the cover is made from the plant which contains a high absorption capacity of carbon
dioxide. The kenaf fibre is evenly mixed with resin acquired from petroleum, allowing it to form shapes of auto parts. The
cover is claimed to reduce car weight by 10% and carbon emissions by 20%.
Floor mats
Mitsubishi Motors Corp has been working with EIDAIKAKO, MRC Pylen and Toyota Tsusho Corp to develop a new floor mat
made using plant-based bio-polyethylene (bio-PE) fibre. The company started production of the new floor mats in summer
2012.
Bio-PE is a plant-based resin made using sugarcane molasses. The company has developed the bio-PE fibre for use in floor
mat piling with an eye toward reducing usage of petroleum-based plastics and cutting CO2 emissions.
As opposed to conventional petroleum-based floor mats, the fibre in this new floor mat has a core-sheath structure in which
the bio-PE core is covered with conventional petroleum-based polypropylene (PP) sheath which allows it to meet the high
levels of performance demanded of car floor mats, including abrasion and heat resistance. In-house calculations indicate
that the new bio-PE fibre floor mat achieves a 15% reduction in life-cycle CO2 emissions over a similar mat made using
petroleum-based PP fibre. The company's current range of plant-based Green Plastics products includes materials made
using liquefied wood-based phenolic resins and interior surface materials which combine PET (polyethylene terephthalate)
and cotton fibres.
Instrument panels
Ford and BASF have teamed to reduce petroleum-based fossil fuel content in the instrument panel of the Ford Focus.
Castor oil is derived from the Ricinus Communis flowering spurge plant, which has widespread growth throughout tropical
regions. The plant's oil presents a sustainable interior foam solution that does not compete with food sources.
Ford maintains the new castor oil-based foam is significantly more durable than the previously used material, with a 36%
better tensile strength, a measure of the foam's ability to hold its shape. Tear strength is improved by 5% while elongation -
stretch under temperature or impact stress - is reduced by almost 12%.
Productivity is improved and the manufacturing process is simplified by the 43% reduction in time for the castor oil-based
foam product to cure. Scrap from this foam product is reduced due to improved flow and processing characteristics.
Ford says it has concentrated on increasing the use of non-metal recycled and bio-based materials whenever possible.
Examples include soy foam seat cushions and gaskets, wheat straw-filled storage bins, recycled resins for under-body
systems, recycled yarns on seat covers and natural-fibre plastic for interior components.
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Interiors
Woodbridge has developed a family of automotive interior products that contain an alternative source of recycled materials.
Recent market advancements in improving recycling capabilities and on-going research efforts by Woodbridge has led it to
working on a new generation of products that contain material sourced from end-of-life tyre materials.
"This effort to develop a family of automotive interior products that would contain ground rubber from used tyres
complements our existing work in offering products with recycled polyols and polyols manufactured in part from renewable
biomass sources,” said Dr Hamdy Khalil, global director of R&D.
Seating
Lear Lear has worked with Ford to introduce a head restraint foam that has 25 percent of the polyol replaced with soy. Seventy-
five percent of Ford's North American vehicles feature bio-foam in the head restraints, including the Ford F-150, Taurus,
Explorer and Fusion. All Ford vehicles built in North America use bio-foam content in the seat cushions and backs. Ford first
used soybean oil-derived seating foam way back on the 2008 Mustang.
The two companies formed a partnership in 2004 to proceed with the development of the technology and the
commercialisation of soy-foam applications, with initial work concentrating on the moulding of headrest and armrest
components.
Soy is, of course, a renewable material and both Ford and Lear are working with the United Soybean Board – New Uses
Committee, which is comprised of a group of 64 farmers and agricultural industry leaders along with Urethane Soy Systems
Co, Bayer Corp and Renosol Corp. The environmental advantages of soy-foam include:
a reduction of carbon dioxide emissions when compared to the current petroleum-based material;
lower energy is required to produce the material;
up to 24 percent renewable content; and
a reduction of dependence on volatile energy markets.
Most automakers today use 100 percent petroleum-based polyol foam. Each vehicle produced today contains an average of
30lbs of petroleum-based foam. The total annual worldwide market for the foam is 9bn lbs. For some time, Lear has been
pushing back the technical boundaries in the area of environmental systems for automotive seating with industry firsts, such
as the use of expanded polypropylene and polyethylene materials. These materials are used in place of traditional
polyurethane foam which offers lower mass and is 100 percent recyclable.
Johnson ControlsJohnson Controls used the 2011 Frankfurt motor show to display its so-called ie:3 demonstrator vehicle, showcasing its
expertise in working with materials and technologies to produce interior components and their surfaces. The materials used
in the ie:3 are sustainable. For example, the seat pads are made from FaserTec, natural fibres embedded into a nonwoven
material and feature a slim profile. JCI says that the weight of individual components can be reduced by as much as 50
percent using this sustainable material.
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Ford Ford is working with Scotts Miracle-Gro CoScotts Miracle-Gro Co to research how coconut coir, or husks, might be used as a plastic
reinforcement. Coconut coir is a natural fibre from the husk of a coconut. Scotts Miracle-Gro uses the material as a carrier
for its soils and grass seed products which use the coir's natural fibres to hold 50 percent more water than basic potting soil
and release it as plants need it. The automaker's researchers combine it with plastic to deliver additional reinforcement to
the part while eliminating the need for some petroleum. Along with making use of a renewable resource, the new part
would be lighter in weight. The natural long fibres also are visible in the plastic and offer a more natural look than typical
materials. In the interior, the material could be used in storage bins, door trim, seat trim or centre console substrates. It
could also potentially be used on underbody and exterior trim. Coconut coir is very difficult to burn and Ford is researching
whether it has natural flame-retardant properties.
In the Japanese market, ToyotaToyota is using a newly developed bio-plastic derived from sugar cane in its new Sai Hybrid sedan.
The carmaker says about 80 percent of the vehicles' interior exposed surfaces including the seats are made from the new
sugar-based bio-material. Toyota developed its bio-polyethylene terephthalate (bio-PET) by replacing monoethylene glycol
(commonly used in PET manufacture) with a biological raw material derived from sugar cane.
Teijin Ltd’sTeijin Ltd’s 'Eco Circle' plant-fibre based bio-polyester is being used in the seats and interior trim surface of the Nissan
Leaf. The supplier says that it is the first time Eco Circle plant-fibre has been used for the interior of a mass-produced
vehicle. The seat and interior trim surface were co-developed by Teijin, automotive seat manufacturer Suminoe Teijin
Techno Co Ltd and Nissan Motor Company Ltd. Specifically, Eco Circle plant-fibre is used for the seats, parts of the door
trim, headrests and centre armrest. Teijin has been expanding Eco Circle plant-fibre’s global market for applications ranging
from apparel, car seats and interiors to personal hygiene products. The company aims to increase sales to over 50 percent of
its total polyester fibre sales for automotive seats and interiors by 2015.
Tyres
Michelin’sMichelin’s Primacy MXM4 passenger tyre incorporates one of the four primary types of sunflower oil - oleic - into its
formulation. The tyre maker claims that the addition of sunflower oil enables the tyre to maintain its edge in wet and
snowy weather.
For its part, GoodyeaGoodyea r's engineers have found in their tests that using soybean oil in tyres can potentially increase tread
life by 10 percent and reduce the tyremaker's use of petroleum-based oil by up to 7 million gallons annually. In addition,
testing at Goodyear's tyre plant in Lawton, Oklahoma showed improved mixing capabilities in the manufacturing process.
The company found that rubber compounds made with soybean oil blend more easily with the silica used in building tyres.
This can improve plant efficiency and reduce energy consumption and greenhouse gas emissions.
BMW's photovoltaic (PV) solar cells
BMW says it is looking at improving efficiency by using solar energy. In Central Europe, a square metre of photovoltaic (PV)
solar cells can produce around 200W of electricity. PV modules could be incorporated into roof, or the whole surface of the
car. The automaker says these could be used to help pre-warm engine fluids to reduce emissions during the cold-start phase,
where emissions are high. BMW says that 1kwh of electricity produced from the sun rather than from the engine would
reduce fuel consumption by 0.3l/100km. The automaker is also looking at using software to take information from the
navigation system and various vehicle sensors to help the engine predict vehicle manoeuvres and improve fuel efficiency
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that way.
Ecological plastic in the Prius
Toyota is using plastic components made from plants for its Prius. Known as ecological plastic, the plant-based foam and
injection-moulded parts are found in several locations throughout the new car including the scuff plates, deck trim and seat
cushions.
The plant-based plastics replace conventional plastics made using petrochemicals, cutting CO2 emissions over the life of the
product (from manufacture to disposal) and helping to reduce petroleum use. Ecological plastic emits less CO2 during a
product’s life cycle because most of the CO2 emitted at disposal was originally captured during photosynthesis while the
plant was growing. Toyota plans to increase the use of plant derived ecological plastic in future vehicles.
Mercedes-Benz uses coconut matting, crushed olivestones and even sawdust
The use of organic materials in cars is not new. For some time, component suppliers and automakers have focussed on
promoting environmentally friendly technologies in all product segments. In the area of seating, for example, coconut fibre
seat pads have been used in order to meet manufacturers’ economic and ecological objectives while contributing to
sustainability.
Mercedes-Benz uses coconut matting, crushed olive stones and even sawdust in certain vehicles. More specifically, the
automaker uses rubberised coconut matting as seat padding in a number of its models. Meanwhile, the crushed, carbonised
olive stones are used as air filtration material inside the fuel tanks of C- and S-Class models, thereby reducing gasoline
vapour smells when refuelling. The vehiclemaker also uses abaca fibres originating from the stem of a banana-type plant
grown in the Philippines. These fibres are used in the underfloor cladding of A- and B-Class cars.
Ford's approach to using alternative materials
Ford says it is reviewing a range of alternatives to products now made with petroleum for potential application in Ford
vehicles. These include shredded retired currency, cellulose from trees, Indian grass, sugar cane, dandelions, corn and
coconuts.
For example, 8,000 to 10,000 pounds of retired paper currency are shredded daily, more than 3.6m pounds annually. The
shredded money is either compressed into bricks and land filled or burned.
Ford's use of soybean-based cushions in all of its North American vehicles including the Fusion, for example, saves
approximately 5m pounds of petroleum annually. The new Escape has door bolsters partially made of kenaf - a tropical plant
in the cotton family - offsetting the use of 300,000 pounds of oil-based resin annuallyin North America.
Ford has concentrated on increasing the use of non-metal recycled and bio-based materials to reduce its dependence onCopyright 2013, just-auto Generated on 11 April 2013 54
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petroleum products.
Plastics and composites
Overview
Bayer MaterialScience sees good prospects for the increasing use of plastics in future mobility technologies, since compared
with conventional materials they save weight, increase efficiency and durability and improve appearance. "The proportion of
plastics in automotive applications should increase from 15% today to as much as 25% by 2020," estimates Hans-Peter
Neuwald from the company's automotive team. "It is not just the weight reduction driving this. It is much more the
emerging economies playing catch-up in terms of quality, safety and comfort." The use of innovative driver assistance
systems, cameras, sensors and products for the protection of pedestrians is another factor favouring the use of plastics.
Today, plastics are used in a variety of vehicle manufacture applications, including dashboards, seats, gauges, switches,
vents, door handles and trim, floor mats, seatbelt and airbags. In addition, there are a number of plastic applications under
the bonnet.
As Bosch points out, plastics replace steel in a number of cases for separate body components. The following table sets out
some examples of alternative materials to steel.
Examples of alternative materials to steelExamples of alternative materials to steel
Source(s)Source(s) Bosch
Examples-of-alternative-materials-to-ste_13612760052390.csv
More and more concept cars on display at motor shows are using transparent body panels. For example, the Chevrolet Volt
incorporates a number of products from SABIC Innovative Plastics, including:
Roof made with Lexan GLX resins and Exatec coating technology;
Rear deck lid and side glazing made with Lexan GLX resins and Exatec coating technology;
Typical applications Material Abbreviation Processingmethod
Structural components, e.g. fendercross members
Glass fibre mat reinforcedthermoplastics PP-GMT Injection
mouldingMouldings/covers, e.g. front apron,spoiler, front section, radiator grill,wheel-well liners, wheel covers.
Glass fibre mat reinforcedthermoplastics PP-GMT
Bodyshell components, e.g.bonnet,fenders, boot lid, sliding sunroof Polyurethane PUR
RIM(reactioninjectionmoulding)RRIM(reinforcedreactioninjectionmoulding)Injection-moulding,
Typical applications Material Abbreviation Processingmethod
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Doors and bonnet made with Xenoy iQ thermoplastic composites;
Global energy absorber and hybrid rear energy absorbers with Xenoy iQ resins;
Steering wheel and instrument panel with integrated airbag chute made with Lexan EXL resins
Front fenders made with Noryl GTX resins; and
Wire coating made with flexible Noryl resins
Automakers are driven to design lightweight cars that will meet increasing fuel efficiency requirements - 54.5 miles per
gallon by 2025 - and satisfy consumer appetite for high-quality vehicles. They're finding that they can lose vehicle weight
and gain styling with engineering thermoplastics and composite materials.
Adopting lightweight polymers and polyurethane composites to replace traditional materials such as glass and metal in
exterior applications, including window glazing and body panel components, can help reduce vehicle mass while retaining
strength.
Bruce Benda, vice president, automotive marketing, Bayer MaterialScience LLC said, "Automakers' 'Drive to 54.5' is
underway. Their challenge to lose vehicle weight and keep it off is creating an ever-greater interest in exploring new
materials and processes that deliver low cost, light weight and luxurious design. The benefits of engineering thermoplastics
and polyurethane composites can help make it achievable."
He points out that by using the company’s Makrolon polycarbonate to replace heavy glass can reduce a vehicle's glazing
mass by up to 50%, helping to cut fuel consumption. Additionally, strong and lightweight polyurethane composite
structures utilised in load floors and roof modules have the potential to trim 20 - 30 pounds of weight in a finished vehicle.
Applications
Airbags
TRW has developed passenger and curtain airbag modules which are up to 50% lighter compared with previous generations.
TRW says the weight saving has been achieved by using advanced materials and production processes in addition to
optimising the design of the module. For example, the supplier’s DI-10 airbag inflator is a disc-type inflator which uses a
new propellant formulation. More specifically, it uses high-grade materials for the housing and weld joint technology to
reduce package size.
TRW Automotive has developed a range of driver airbag modules made of regenerative plastic material, which offers a
number of environmental benefits. TRW claims it is the first to develop the new, greener module where components,
including the airbag cover and retainer plate, are now made from a new, bio-based material.
Meanwhile, TRW's new SHI2 curtain airbag inflator offers flexible packaging, which allows it to be tailored to individual
customer and market requirements.
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Bioplastic for vehicle interior parts
A bioplastic which can be used for car parts has been developed by an industry-government-academia joint research project
based in Hiroshima Prefecture and involving Mazda. The automaker claims that the bioplastic, which is made of natural
materials, offers improved exterior surface quality and high-strength. It can also be used for vehicle interior parts.
Mazda points out that it has three times the shock impact resistance along with 25 percent higher heat resistance when
compared to contemporary bioplastics used for items such as electrical appliances. In addition, it is made with a
fermentation process that includes natural materials such as fermented starches and sugars which, compared with the
process to make polypropylene, reduces energy use by 30 percent.
Brake pedal
In cooperation with Lanxess and Bond-Laminates from Brilon, Germany, ZF’s engineers have developed a brake pedal based
on nylon composite sheet and polyamide 6.
Claimed benefits of this system is that it is 50% lighter than comparable brake pedals made of steel, but has the same
mechanical strength. Weighing just 355 grams, this concept component is the world's first car brake pedal made of
polyamide reinforced with continuous glass fibres that is suitable for large-scale series production.
The partners point out that the brake pedal in nylon composite sheet hybrid technology is easier to manufacture than
comparable pedals of sheet steel, which usually consist of several sheets. For example, the new technique eliminates the
need for the complicated forming, cutting and welding processes required with sheet metal.
Bumper market
A number of material innovations in the bumper area have emerged recently. For example, Renault Renault is using ExxonMobil
Chemical’s Exxtral TPO (thermoplastic olefin) for the front and rear bumpers of the Renault Laguna Coupe. Renault says
Exxtral TPO meets its specifications for excellent fit and finish, along with good impact strength and a balance of stiffness
and toughness that is required for automotive bumpers. Volkswagen has used a similar grade for the bumpers on its new
VW Golf and Renault has used these materials on the 2006 Espace and 2007 Laguna.
Meanwhile, US-based Mill iken ChemicalMill iken Chemical has developed a reinforcing agent for polyolefins that reduces part weight by as
much as 15% versus mineral-filled systems and is said to deliver a good balance of stiffness and impact strength. Milliken
says that its so-called HPR-803 is capable of replacing glass-reinforced PP or expanding automotive applications for PP
beyond the current hidden structural automotive applications to include highly visible components like bumpers and door
panels.
On the recycling front, Mazda MotorMazda Motor says is has developed a system which enhances the process it uses to recycle used
bumpers into raw plastic resin for use in new vehicle bumpers. It said the new technology is the first to enable recycling of
used bumpers from different manufacturers at the same time. The automaker has recycled bumpers since the early 1990s,
initially turning them into underbody trays. The latest recycling technology can recycle all types and makes of bumper,
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removing the need for separate collection systems for each automaker’s products.
Engineers at Mazda Motor and Japan Polypropylene Corp worked together to develop a resin material for vehicle parts. The
partners claim this material maintains the same rigidity as front and rear bumpers made with conventional materials while
reducing weight by 20%. “In the bumper production process,” says Mazda, “this reduced thickness allows for a shorter
cooling period for moulding and, by using computer-aided engineering technology, the fluidity of the resin material has also
been optimised. As a result, bumper moulding time, previously 60 seconds, has been halved to 30 seconds, leading to major
reductions in the amount of energy consumed in the production process." Mazda plans to adopt the claimed lightest
bumpers in the class using this new resin material in the new CX-5 SUV as well as other planned new models. Bumper
weight has a major impact on fuel economy and driving performance, the automaker added. They also are multi-functional,
requiring both rigidity to absorb impact, and moulding and painting properties suitable for attractive exterior design. The
new material blends two components found in polypropylene and rubber, the constituents of resin, that have different
properties, and distributes them in a double-layer structure in line with the required function for the surface and the inside
of the base bumper material. As a result, the surface has excellent paint film adhesion and the inner section retains high
rigidity and impact absorption, with reduced thickness.
In August 2012, SABIC's Innovative Plastics SABIC's Innovative Plastics announced that Mahindra & Mahindra, with support from Plastic Omnium,
has developed India's first injection moulded plastic fenders, which are featured on the XUV500 SUV model. The fenders
incorporate SABIC’s Noryl GTX resin. SABIC claims that the resins' ability to withstand the high temperatures of online
painting allowed the fender to be integrated into the production process, while the material's inherent conductivity avoids
the need for a conductive primer step.
SABIC Innovative Plastics’ Noryl GTX 989 resin is being used in the front fenders of the 2013 Mitsubishi Motors Outlander
Sport crossover. The vehicle's fenders are the first to be produced using 2-cavity injection moulding with Noryl GTX resin,
allowing carmaker to cut cycle times in half and reduce tooling costs. Other claimed benefits of the SABIC material include
weight savings versus steel for fuel economy gains and sustainability benefits and flexibility to design the first North
American fenders with integrated pedestrian head impact absorption brackets.
Plastic OmniumPlastic Omnium has developed a bumper using recycled plastic. The patented process uses polyolefin collected through
recycling channels (mainly auto industry manufacturing waste and crushed parts) to produce a recycled plastic that, PO
claims, delivers the same technical performance in terms of impact resistance and paint adhesion as parts made with new
plastic. Since 2006, regulations have required that 85 percent of a vehicle’s weight be reusuable as recycled material or
energy, a figure that is expected to rise to 95 percent in 2015.
Charge air ducts
In June 2012, BASF announced that a plastic compound developed by the company has, for the first time, found use in the
charge air section of a commercial vehicle. The charge air duct on the DD13 /DD15 truck engines is one of the first large
production applications for the new polyamide (PA) grade Ultramid A3W2G6. The component, which is produced by
ElringKlinger from the very heat aging-resistant PA, offers high mechanical and thermal capabilities. The multifunctional oil
intake module is also manufactured from a BASF polyamide. The designation DD13/DD15 covers a range of high-
performance truck diesel engines with a displacement of about 13 and 15L, respectively, that Detroit Diesel Corporation,
truck engine and component manufacturer and Daimler subsidiary, builds in the USA.
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Composite material door panels
Faurecia designs and manufactures door panels using composite materials that combine wood fibres with polyolefin or
polyester. These materials contain 63 - 73 percent of natural fibres. Instrument panels are also produced combining linen
fibres and a polypropylene matrix. These use 40 - 60 percent natural fibres, depending on the mechanical properties
required. The use of natural fibres as reinforcement in plastic parts brings weight savings of 25-30 percent.
Faurecia is one of the few automotive equipment suppliers in the world to have developed such materials, which are used in
both premium vehicles and volume-production models such as the Citroën C4, Toyota Corolla and Avensis, Audi A4, Ford C-
Max and Volvo C70 Coupé (wood fibres), and the Opel Astra and SmartForTwo (linen).
Composite plastic tailgate
Plastic Omnium Auto Exterior manufactures some 2,500 plastic tailgates daily, making it the European market leader. Once
of its recent innovations is a lightweight hybrid tailgate that combines thermoplastic and composite technologies. The
supplier claims the tailgate helps reduce vehicle weight by up to 10 kilograms. The company says it has received a number
of orders for this technology.
Door panels
During an interview with William Hanna, vice president and executive director of Inteva Products’ Closure Systems business
about trends in car door design and build, we asked about the extent to which composite materials – including natural
materials - being used (or could be used) in doors?
“Composite materials are being used extensively inside of doors, and have been for many years. In the mid-1990s Inteva
introduced a groundbreaking development and implementation of the SuperPlug, a plastic door module that eliminated 60
components from within the door. The SuperPlug module is currently considered a top product and will be inducted into the
Hall of Fame this year by the Society of Plastics Engineering for its contributions to composite material utilisation in doors.
“Inteva also experiments with different recycled materials to create new developments. Composite material products and
processes dominate a door’s Bill of Materials in today’s vehicles since technological advancements in composite materials
offer structurally sound and energy absorbing alternatives to traditional steel components.
“With an increased emphasis on improved emissions, mass reduction, and cost savings, composite materials offer OEMs the
ability to meet their objectives. Composite materials are enablers for improved quality as many features and components
can now be integrated in ways that are impossible using traditional metal components, thereby reducing system variation
and improving overall performance of your door’s subsystems.
“Natural materials have their place in the market as well, although at the moment are not as typical or popular as
composite materials. Natural materials such as wood fibre can be incorporated into trim products but usually are not
structurally sound enough to be used in door module applications.”
Meanwhile, Johnson Controls is supplying door panels, seat structures and instrument clusters for the BMW 3 Series. TheCopyright 2013, just-auto Generated on 11 April 2013 59
door panels are made using a combination of natural fibres and plastic that are 20% lighter than conventional components,
while the seat structures on the driver's side save 3kg to 4kg depending on the model. The instrument cluster features an
Automotive Pixel Link point-to-point connection. The non-visible door panel elements for the new BMW 3 Series sedan and
sports wagon models are largely made of wood fibre, while the natural fibre carrier is directly moulded with plastic. This
method makes the door panel considerably lighter. A process known as groove lamination is used to apply the fabric or
leather trim on the door panel, involving the trim being joined in recesses, eliminating the need for an additional component
and further reducing weight.
Environmentally friendly (‘green’) products
The main raw materials used to manufacture automotive products include aluminium, copper, resins and steel.
For the past three years, component manufacturers have faced commodity cost increases, most notably copper, aluminium,
petroleum-based resin products, steel and steel scrap and fuel charges. Consequently, they have sought to manage these
and other material-related cost pressures using a combination of strategies, including working with their own supply base to
mitigate costs, seeking alternative product designs and material specifications, changing suppliers and hedging of certain
commodities.
The demand for environmentally friendly (‘green’) products used in vehicle manufacture continues to increase unabated.
Such products represent technologies designed to help reduce emissions, increase fuel economy and minimise the
environmental impact of vehicles.
Vehiclemakers continue to focus on improving fuel efficiency and reducing emissions in order to meet increasingly stringent
regulatory requirements in various markets. As a result, suppliers are competing intensely to develop and market new and
alternative technologies, such as hybrid vehicles, fuel cells, and diesel engines to improve fuel economy and emissions.
ESP applications
Bosch’s electronic stability programme, ESP 9, has a control housing molded from BASF’s hydrolysis-resistant Ultradur
B4330G6 HR. BASF claims that this compound retains its material properties such as high strength, elasticity and impact
strength during long-term testing at 85°C and 85% relative humidity. It withstands test periods of over 5,000 hours without
noticeable characteristics of aging. This is several times longer than the hydrolysis-resistant PBT used to date, claims BASF.
An additional benefit of the compound, says BASF, is its stability during processing.
Front-end modules
A stripped down version of Chang’an Automobile’s CX30 model was displayed at the 2011 Shanghai motor show. It
featured plastic front-end module using SABIC Innovative Plastics’ so-called stamax long glass fibre polypropylene resin.
The innovation is claimed to have cut part weight by up to 40 percent and total vehicle weight by about four kilograms. The
FEM integrates the radiator, headlamps, lock bridges and bumper beams.
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Fuel system applications
Solvay Advanced Polymers has developed a new grade of its Ixef polyarylamide resin for use as a low permeation material in
a range of automotive fuel system applications. The major advantage of the new polyarylamide grade is that only two
layers are required to meet the barrier property standards of the US Environment Protection Agency’s (EPA) Partial Zero
Emission Vehicle (PZEV) and the California Air Resources Board (CARB) automotive and small off-road engine emission
regulations. According to Solvay, unlike other popular barrier materials such as ethylene vinyl alcohol copolymers (EVOH),
where four layers are needed to achieve a satisfactory barrier resistant properties, polyarylamide only requires two layers,
representing savings in material and production costs. Solvay says its polyarylamide is aimed at small fuel tank
manufacturers serving commercial and consumer markets for lawn tractors, marine craft and motorcycles. It is also
targeting the North American and European OEMs for use in vehicle fuel systems, including tanks and filler tube parts.
Given the challenges that vehiclemakers face with the corrosive nature of biofuels and finding materials for automotive fuel
systems that are resistant to them, Basell has developed a high density polyethylene resin which, it claims, is suitable for
use in automotive fuel tanks with enhanced resistance to biodiesel fuel. “We are responding to the automotive industry’s
demands for resins that can address their alternative fuel technology needs,” said Thomas Lindner, customer programme
manager for Basell’s plastic fuel tanks programme. “Lupolen HDPE test data using blow-moulded and injection-moulded
specimens has shown a dramatic increase in chemical resistance to biodiesel fuels compared to current HDPE grades on the
market.”
The Mercedes-Benz E Class has a large fuel filler flap, since it is intended to accommodate variable fuelling options. This flap
has been converted to the new Ultramid TOP 4000 from BASF, a mineral-filled semi-aromatic polyamide (PA 6/6T). The
conductive engineering resin is said to be an improved version of the Ultramid TOP 3000, offering greater stiffness and
dimensional stability.
General Motors' 'smart materials' developments
General Motors’ scientists at the vehiclemaker’s research and development centre in Warren, Michigan have claimed a
technological breakthrough in so-called smart materials.
These shape memory alloys and polymers can change their shape, strength and/or stiffness when heat, stress, a magnetic
field or electrical voltage are introduced. This opens new possibilities for many movable vehicle features, as shape memory
alloys, and polymers in particular, ‘remember’ their original shape and can return to it.
“Smart materials will change the look and feel of our cars and trucks,” said Larry Burns, GM vice president of research and
development and strategic planning. “With these new materials, functionality can be ‘programmed in’ to enable innovative
designs, improved efficiency, and new and improved features that will make our vehicles more exciting to own and operate than
the automobiles of the past.” Actuators and sensors made from these materials have the potential to improve vehicle
performance and fuel economy, as well as enable new comfort and convenience features. These actuators and sensors can
provide significant benefits when used to replace conventional motorised or hydraulic devices by reducing vehicle mass,
component size and complexity, as well as improving design flexibility, functionality and reliability. A few example
applications include active vehicle surfaces, such as spoilers and air inlets that adjust to govern airflow; improved
aerodynamics and performance; as well as hood, door latch and glove compartment releases for more convenient access.
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According to Alan Taub, GM executive director of research and development, smart materials are building on previous
materials advances GM has introduced over the last several years. “These new smart materials follow a long list of material
applications we are already using,” said Taub. “A few examples include novel aluminium forming processes that provide
enhanced body panels and lightweight, polymer nanocomposites that provide superior mechanical properties at lower cost, and
magnetorheological fluids for improved chassis systems. “The properties inherent in shape memory alloys and polymers have the
potential to be game-changers in the automotive advanced materials field, eventually leading to vehicle subsystems that can
self-heal in the event of damage, or that can be designed to change colour or appearance.”
Smart materials are being used in other industries in various applications including medical devices, mobile phone antennas,
toys and sporting goods.
Glass fibre compounds
Borealis has developed a range of glass fibre reinforced polypropylene (PP) compounds. The company claims that its so-
called Xmod GB306SAF is specifically tailored for the manufacture of air intake manifolds and other engine compartment
components exposed to high loads and peak temperatures of up to 140°C. Volkswagen was the first vehicle maker to switch
from glass reinforced polyamide (PA) to PP for its air intake manifold application, now used in a variety of its car models
with engine sizes from 1.4 to 1.6 litres. Borealis Xmod GB306SAF was chosen by part manufacturer MAHLE Filter Systems
UK and VW to meet their needs for lower system costs without significant changes in tooling, part design or equipment
investment, as well as improving acoustic part behaviour and the use of a more environmentally-friendly material.
Glazing
Although the idea of replacing glass with lighter-weight plastic sounds like an obvious innovation, it is not new. For over 30
years, auto glass experts have explored the potential for polycarbonate as a replacement for glass.
Compared to the shape limitations of glass, plastic (polycarbonate) glazing is highly versatile. It is also lighter by as much as
50% and has high impact resistance. Suppliers claim that a total weight reduction of more than 20kg (50%) is possible
when replacing all glass windows (except the windshield) for a standard minivan. Vehicle manufacturers can now consider
3D-shaped windows, innovative designs and locations and new opening and closing mechanisms.
An auto executive told us: “Polycarbonate is something that we continue to pay attention to. We view our business as we create
glazings so whether those glazings are made out of glass or glass-plastic or plastic, then that is our business. So we pay a lot of
attention to that. We work with a lot of the companies in the supply chain for plastics or involved in the technology for
manufacturing the systems. At the [2009] Detroit auto show, we saw a polycarbonate glazing on the Mercedes GL. That is a
relatively small piece. There was also a polycarbonate roof on a Smart car. And we continue to see [polycarbonate] on some of
the concept vehicles. But at this point in time, we still view it as a technology which has a lot of promise based upon weight but
there are still a number of issues that prevent it from becoming a high volume, broad-based technology. We think that it will
continue to stay as a niche for certain vehicles where it makes sense. But we still see that glass and glass-plastic are going to have
the leading share of the market for the foreseeable market. There are still some issues to address. As those polycarbonate pieces
become bigger and bigger, how do you deal with the rigidity of the plastic, given that it is so lightweight then that gives us
potential structural issues as we go forward? Will these issues be solved in the future? Well, a lot of people of working are on it. If
and when the material is ready then we intend to be there.”
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An auto executive of a manufacturer of roofs for convertible cars told us: “Currently there is no competitive material for
convertibles – performance and costs are still better with glass. We would be interested in polycarbonate due to the low weight
and the possibility of integrating other functions in the glass with injection moulding. Scratch resistance is still a problem,
however, regarding the costs. Other problems are heating of the backlight and UV resistance. [Cost] is one of the reasons why we
are not using the material at present. It is not the polycarbonate material itself which creates the high costs, it is the coating and
additional features like heating.”
Another auto executive told us: “The raw materials to produce polycarbonate are more expensive than the raw materials to
produce glass. So the cost advantage will always be on the glass side. Also, glass has the benefit of a good scratch resistance and
heat extension coefficient. Then you have problems with chemical resistance – if you smoke inside the car or apply stickers to the
inside of the polycarbonate glass then it creates problems.” In discussing the potential vehicle glazing applications of
polycarbonate, this auto executive added: “I am not a specialist in polycarbonate glass but I am aware of certain acoustical
issues, i.e. the larger the surface area of the polycarbonate glass then the more the acoustic problems that you get into. And then
there is concern with the crash behaviour of the polycarbonate. I know that companies have been trying to sell polycarbonate into
the automotive market for the past 25 years. It didn’t really take off very well.”
An auto executive for a European vehicle maker told us: “PC glazing is now a major solution that can be applied to cars. It
cannot be applied everywhere such as windscreens and front windows because there are still some regulations which prohibit
this application. But on rear side windows and rear windows and roofs then we could consider this type of glazing. It is now
mature enough to seriously consider using it. However, these types of alternative technologies are still quite expensive. And it
has to be applied very carefully. It is certainly true to say that it does give some new opportunities given the style and shape of the
glazing but the price is not so low that we can apply it more widely. These PC glazings are being validated for sure. We now know
what we can do with these [PC] glazing technologies as well as its limitations. So it is now a question of using PC for a smart
application, not just using it for the sake of using it. The problems of scratch resistance and UV resistance have, to a large extent,
been overcome. Although the material is not as good as glass, it is resistant enough to be used as a glazing application.”
In terms of the acoustical behaviour of polycarbonate glazing, this executive added: “It does not behave in the same way as
glass but, considering the noise comparison, it is not noticeable. There is also a size limitation with PC roofs. Because it is
injection moulded, you cannot have quite so large roofs as you can when you use glass. But there again, in the case of a moveable
roof, half of it could be made using PC glazing if we wanted to.”
In terms of whether or not we could expect to see more pieces of PC in the next few years, the executive concluded: “Well,
we know what we can achieve in PC solutions. But it does not mean we will use it widely. It depends on the car and the
opportunities. It is about choosing the right technical solution – either glass or PC – for the car bearing in mind the price.”
An auto executive of a glass maker told us: “My understanding of polycarbonate is that it has a problem with longevity in terms
of weathering under sunshine – it makes it check and crack. Historically in the hurricane impact market, polycarbonate was a
product of choice for many years when we didn’t have the experience of how to make a laminated glass perform. And quite
frankly, the polycarbonate product has gone away. It is not anywhere near as prevalent as it used to be. It still has a lot of issues
with checking and cracking with hazing over time. It is susceptible to some scratching so running it through a car wash means
greater potential for scratching. That said, there is a use for the product. A single layer of PC in a roof would probably work. But
the longevity of that would probably be an issue.”
Another auto executive of a glass maker told us: “Polycarbonate will continue to be a technology of interest. The challenges of
rigidity and durability continue to be issues that have to be addressed for widescale adoption. Also, the issues of heat load
reduction and solar protection are becoming more and more prominent. That is the compromise that they have to deal with. You
can get polycarbonate glazing in, say, the non-consumer contact positions. But the solar performance today is so poor thatCopyright 2013, just-auto Generated on 11 April 2013 63
polycarbonate industry has been asking CARB to provide special exemptions for polycarbonate for solar performance which
CARB has not been willing to do so far. So solar performance is a major issue.”
SABIC Innovative Plastics used a VDI Conference in Mannheim, Germany to reveal new findings on the benefits of its Lexan
polycarbonate glazing, helping to improve efficiency for conventional, hybrid and electric vehicles. “With this new research,
we have given the industry a whole new way to think about the value of Lexan polycarbonate glazing, beyond the well-
known benefits of weight reduction and styling freedom,” said Dominic McMahon, general manager of Automotive Product
Marketing at SABIC Innovative Plastics and CEO of Exatec. “The significance of our findings is that automotive OEMs can
get even more out of our portfolio of Lexan polycarbonate glazing solutions – benefits like extended range for electric
vehicles and greater efficiency in air conditioning and heating systems. These findings also represent a natural complement
to the solar energy absorbing capability of our infrared absorbing Lexan resins, which can be used to further reduce the heat
load on a vehicle’s interior.”
For its part, Bayer MaterialScience is developing material solutions based on polycarbonate and polyurethane, which can be
in the areas of glazing and the roof structure. These materials enable weight reductions of up to 50% compared to glass, as
already demonstrated by the use of polycarbonate panoramic roofs or fixed side windows in series production.
Bayer MaterialScience has developed transparent tinted colours specifically for polycarbonate glazing that filter out a large
proportion of the sun's infrared (IR) rays. As a result, the vehicle interior does not heat up as much under the effects of
sunshine. Appropriately treated glazing made of Makrolon AG2677 enables IR light and energy transmission values for dark
colours that are at least as low as commercial thermal insulation pigments for glass.
IAC develops blow foaming process for air ducts
International Automotive Components (IAC) has developed a blow foaming process for HVAC duct components to be
featured on a model year 2014 North American vehicle. IAC's manufacturing facility in Madisonville, Kentucky will provide
air ducts for the programme, and annual volumes in the first year are expected to be some 100,000 units. Claimed benefits
of the new blow foaming process include:
eliminates the need for secondary foaming pieces and reduces part count required in typical blow moulding processes,
thereby reducing manufacturing costs; and
reduces BSR (buzz, squeak and rattle) and provides improved NVH characteristics due to its improved sound absorption
properties, reducing airflow noise by an estimated 30 percent when travelling through the duct.
Blow foaming was introduced in Japan by JSP in 2002 and the arrangement for distribution and licensing in North America is
exclusive to IAC for this programme. In addition to air duct applications, other vehicle applications are under consideration
says IAC.
Interior applications
BASF Polyurethanes’BASF Polyurethanes’ chemists have developed two polyurethane (PU) solutions, namely, Elastoskin, the in-mold-coating
(IMC) spray skin, and Elastollan, the hard-phase-modified aliphatic thermoplastic polyurethane. Both surface materials
provide a luxurious look feel for premium car interiors. For example, the Mercedes-Benz S and SLK class vehicles feature anCopyright 2013, just-auto Generated on 11 April 2013 64
Elastoskin surface in the cabin.
Meanwhile, ElastollanElastollan is an aliphatic TPU with a broad hardness spectrum introduced into the market way back in
2007.The special feature of Elastollan, says BASF, is that its feel can be precisely set to match customer specifications and
to meet the application requirements by fine-tuning the interaction of the shore hardness value with the surface design. The
centre console of the VW Golf VI is made by means of two-component injection molding with PC/ABS
(polycarbonate/acrylonitrile butadiene styrene copolymer) as the underlying component. This component surrounds
functional elements such as the storage compartment, ashtray, air-conditioner control element, rolling cover of the cup
holder and chrome ornamentation on the gearshift cover.
The new Toyota YarisToyota Yaris has an improved cabin, in terms of design, specification and materials quality. “Quality is being
driven in that direction by the increasing sophistication of the customer in the B segment,” said Toyota Europe's
manufacturing purchasing chief, Mark Adams. Speaking on the sidelines of a media presentation at the French plant in
Valennciennes that makes the Yaris, he said a rising number of customers for that B segment car were migrating down from
the C segment (Auris, Golf, Focus, etc) and bringing their expectations with them. Hence items like multimedia system,
Bluetooth, panoramic glass roof and dual zone automatic climate control. Using fewer suppliers for more parts has also
helped, Adams said.“From a sourcing strategy, we've tried to source the complementary parts in the vehicle cabin from the
same supplier and that means they tend to be using the same toolmakers and therefore you see a greater degree of
'complementation' in the plastic finishes in the cabin. Much of the facia (dashboard) plastics are sourced from the same
factory and therefore we can tune the quality to be complementary.” What the customer perceives as “better quality” is
not necessarily provided through using “more expensive materials”, Adams added. Different materials or different surface
treatments can make a difference. “We heard loud and clear criticism on previous [Yaris] models of too much hard plastic
that, when tapped, made a noise like a drum. To provide new materials which are perhaps a little softer, a little more
forgiving in their aspect, a little deeper in the grain pattern, maybe with the application of some soft-touch finishes as well,
is not enormously more costly to provide, it's just a different solution to provide.” He said the previous design wasn't
necessarily borne out of an economic need but a perception of what the customer wanted and that had changed.
'Scaratchability' had been an issue, along with 'cleanability' and that was now being factored in to materials selection.
The Woodbridge GroupThe Woodbridge Group has developed a polyurethane composite board to be used on load floors, deck lids, package
trays, sun shades and seat backs. Claimed benefits of the group’s so-called StrataTRIM technology include system cost
savings, design flexibility, enhanced surface quality, improved acoustics and up to 50% mass reduction. StrataTRIM products
are available across North America and more recently in China through the joint venture partner Wuxi Jixing Auto Parts. The
new joint venture, named Wuxi Woodbridge Jixing Advanced Polymer Technology, represents the first Stratas product line
expansion outside of North America, for The Woodbridge Group.
Resins
Invista Engineering Polymers is ofering its so-called Torzen Marathon PA66 resin to the plastics market. The company says
this new engineering polymers resin grade responds to the market's demand for a resin with higher continuous use
temperature resistance while allowing for enhanced processing for applications in the automotive segments.
"As a result of the automotive sector's efforts to improve fuel efficiency through light weighting, we are seeing increasing
use of applications such as turbo-charged engines, which require greater temperature resistance," said Kurt Burmeister,
executive vice president of Invista Engineering Polymers.
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Roof systems
US-based Asahi Kasei Plastics’ Asahi Kasei Plastics’ Thermylene family of short-fibre polypropylene resins is being used in a sunroof module
designed and built by Inalfa Roof Systems for the Cadillac CTS. The square metre roof marks the automotive industry's first
fully integrated sunroof module made entirely from glass fibre reinforced PP and replacing long-glass PP and short-glass
ASA/PBT. The company claims that using its material results in a 12% weight reduction, a 24% savings in component cost
and a 47% savings in capital costs.
For its part, Bayer MaterialScience Bayer MaterialScience is developing material solutions based on polycarbonate and polyurethane, which can
be in the areas of glazing and the roof structure. These materials enable weight reductions of up to 50% compared to glass,
as already demonstrated by the use of polycarbonate panoramic roofs or fixed side windows in series production.
A roof module with glazing and integrated solar modules was developed as a prototype component and concept study by
Webasto AG. The roof module's low weight is thanks largely to the lightweight panoramic panel. This consists of the
transparent polycarbonate Makrolon AG2677, developed by Bayer MaterialScience for automotive glazing.
"Automotive glazing made using our polycarbonate can make a key contribution to offsetting the continuing heavy weight
of batteries for electric cars," says Dr Sven Gestermann, key account manager for automotive glazing at Bayer
MaterialScience. "A key aim of current developments is to significantly extend the travel range of vehicles. Automotive
manufacturers are therefore showing great interest in glazing systems based on our plastic."
Bayer MaterialScience has developed transparent tinted colours specifically for polycarbonate glazing that filter out a large
proportion of the sun's infrared (IR) rays. As a result, the vehicle interior does not heat up as much under the effects of
sunshine. Appropriately treated glazing made of Makrolon AG2677 enables IR light and energy transmission values for dark
colours that are at least as low as commercial thermal insulation pigments for glass.
SABIC's Innovative Plastics' SABIC's Innovative Plastics' collaboration with CK Technologies and Volvo Trucks North America resulted in the
trucking industry's first injection-moulded roof fairing, now featured on all 2013 Volvo heavy-duty trucks. SABIC says the
roof fairing demonstrates the feasibility of replacing traditional thermosets with thermoplastics to reduce weight and
energy requirements for manufacturing and enable recycling.
Before SABIC, CK Technologies and Volvo Trucks produced this new injection-moulded thermoplastic roof fairing, it was
believed that only thermosets were capable of forming such large parts with the desired structural strength and stability to
withstand the rigorous demands of trucking operations. However, thermosets presented a number of drawbacks, notably
VOC emissions from secondary coating operations; lack of ductility that could lead to shattering and the need for time-
consuming repairs; heavy weight that contributed to higher fuel consumption and CO2 emissions; and an inability to be
recycled. SABIC claims that injection moulding Cycoloy resin using IMC technology solves all these challenges.
Sealing applications
Material from Treleborg
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Sweden’s Treleborg has developed a polyurethane material for automotive applications. Its so-called Zurcon Z25 is used for
heavy duty cylinder sealing applications. These include industrial and mobile applications with limited cooling systems or
cylinders exposed to high-temperature painting processes. Claimed benefits of the material include the ability to operate at
higher temperatures than traditional polyurethane materials.
Windshield sealing system for the Opel Astra GTC
BASF developed and now supplies the windshield sealing system for the Opel Astra GTC. BASF Polyurethanes’ so-called
COLO-FAST_ WST (Window Spray Technology) is a system for pressureless application to glass in an open mould. This flush
glazing technology is only possible with polyurethane, says BASF. The result is glass and panorama roofs with flush seals and
glass panes. Splifar in Belgium is the first company to be granted a license by BASF for COLO-FAST -WST technology and to
invest in a production installation. Production has been underway since the end of 2010.
After taking over the window encapsulation business from Recticel in 2009, BASF has been developing its COLO-
FAST system. The company is aiming to apply this technology to large, complex windows (of laminated or toughened safety
glass) on cars and commercial vehicles.
Seat belts
Key Safety Systems is using Hostaform S polyoxymethylene (POM) for safety systems in Volkswagen's up! vehicle. The
Hostaform S POM has been provided by Ticona. The ratchet wheel of the seat belt retractor system, along with the ejector
in the belt buckle, have been manufactured using Hostaform S9364 XAP², as the material is able to absorb high forces while
retaining strength and stability, according to Plastics Today. The Hostaform is chemical and scratch resistance, high-
temperature dimensional stability, similar to materials used in vehicle interiors.
Seats
The Opel Astra OPC sport coupe has a seat pan made from a thermoplastic laminate with continuous fibre reinforcement
(organo sheet), supplied by BASF. This is the first auto seat pan to be based on this technology manufactured for a
production vehicle. The plastics used are polyamide specialties from BASF's Ultramid product range. The seat pan is 45%
lighter than its predecessor.
Suspension system
ContiTech is offering a modified air suspension system for the Mercedes Actros, which is also available for the independent
replacement market. The air suspension system has a plastic cone plate vulcanised into it instead of a conventional plate
made of steel. The weight savings are claimed to translate to a higher payload for the fleet operator and helps reduce fuel
consumption and CO2 emissions. Furthermore, the plastic cone plate cannot corrode, which cuts maintenance costs.
Meanwhile, Sogefi is offering suspension springs made from composite materials. The supplier has patented a new type ofCopyright 2013, just-auto Generated on 11 April 2013 67
coil spring made from fibreglass reinforced plastic (FRP) which weighs between 40 and 70% less than the traditional steel
springs. The new springs, which can be mounted on cars and light commercial vehicles, make it possible to reduce the weight
of cars by four to six kilos, with resulting benefits in terms of lower consumption. Audi was the first manufacturer to accept
Sogefi's FRP Coil Springs. Following joint development work, the FRP coil springs have been adapted to Audi's requirements
and will find use in an upcoming model.
Transmission crossbeam
ContiTech Vibration Control has developed a transmission crossbeam made of fibre-glass reinforced polyamide, which BMW
uses in its 5 Series Gran Turismo 550i and in the 750i as standard. The plastic transmission crossbeam weighs 50% less than
conventional components. The transmission crossbeam with integrated transmission mounts is the direct link between the
engine-transmission unit and the chassis.
Tomorrow's car
Regarding tomorrow's car, LanxessLanxess head of R&D Dr Werner Breuers believes that intelligent chemical materials will play a
key role in achieving sustainable mobility.
He said, "In a few years' time, we will be sitting in vehicles whose environmental credentials, efficiency and performance are
shaped to a large extent by innovative materials from Lanxess. This is true, for instance, of our rubbers, which can be used to
produce fuel-saving, low rolling resistance tyres, and our high-tech plastics, which can be processed into lightweight
components with a high load-bearing capacity for car bodies, for example."
"We have developed special-purpose rubbers and rubber additives that help cut the rolling resistance of tyres by up to 30
percent without having a negative impact on their wet grip and service life," added Breuers.
Reducing rolling resistance to this extent cuts the fuel consumption of a passenger car - with a gasoline engine and average
fuel consumption of 10 l/100 km - by half a litre per 100 km and its CO2 emissions by 1.2 kg per 100 km.
"We expect that the share of these high-performance tyres compared to normal tyres will rise by 77 percent by 2015. They
will soon be standard in Europe," said Breuers.
In addition to "green" tyres, systematic lightweight construction also helps cut vehicle fuel consumption and CO2 emissions.
Intelligent material concepts based on lightweight plastic are especially popular. In Europe, for instance, around 15 percent
of a vehicle's weight is currently made up of plastic parts.
"Given the trend towards electric cars, we expect this figure to increase to 25 percent in the near future, because the heavy
weight of the batteries has to be compensated elsewhere to ensure that electric vehicles have an acceptable range," stated
Breuers.
Breuers expects that the plastic/metal composite technology based on metal and Durethan polyamides, also known as
hybrid technology, will prove invaluable.
This is because hybrid components are usually 20 to 30 percent lighter than pure steel components delivering the same
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performance.
The ITB GroupITB Group hosted its 2011 series of automotive interior seminars with two back-to-back events in Shanghai and
Detroit.
Learning sessions at the conferences focused on today's needs in the automotive interior, including consumer desires,
instrument panel skin technologies, efforts toward mass reduction and ‘electronification’ of the centre console and displays.
Carmakers led the presentations of the current aesthetic and styling directions needed to delight American and Chinese
consumers.
In particular, Chery and SAIC Motor set out their vision on the role of design and the combined effect of visual, olfactory,
tactile, and auditory cues in the cockpit. At the North American conference, Chrysler shared its internal struggles and
successes for implementing a sensible interior development process.
Other presenters included systems expert FRIMO, who explained technologies for in-mould graining of the instrument panel.
Mould specialist Weber Manufacturing also showed a technology for fine surface detail, known as nickel vapour deposition.
Materials supplier Arkema discussed decoration of PVC slush instrument panel skins, while Benecke-Kaliko introduced its
Benova brand coverstock and Acella Lux laminates. Faurecia showed a range of surface and decoration solutions that can be
used in Chinese interiors.
Another notable topic at the conference event was the continued electronification of the interior, with needs for functional
decorative surfaces and touch displays that most effectively serve the driver. Bayer MaterialScience instructed the audience
on film insert moulding to create centre stack surfaces with capacitive switches and formable hard coats to improve scratch
performance.
Automotive centre stack supplier Preh noted the many competing HMI technologies in the interior, and put forth an elegant
interior concept that integrates a centre console controller with a smartphone-esque touchpad. Leggett and Platt surveyed
the state of wireless charging for smartphones, a technology that is now gaining traction at the OEMs.
Steel
Overview
Mild and high strength steels are used in a variety of vehicle manufacture applications, including chassis, body-in-white,
door beams and roof structure. Steel is also used in a number of other areas to accommodate the engine or other parts, For
example, exhausts are typically made from stainless steel.
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For some time, the automotive industry has been under pressure to change the way it designs and builds vehicles, due to
factors such as the increasing impact of passenger and pedestrian safety requirements and the competitive intensity caused
by globalisation and manufacture in low cost economies. Governmental pressure in Europe and North America to reduce the
CO2 emissions has also prompted automakers and their supply base to develop automotive technology to meet those strict
emission limits. Consequently, more and more vehicles are incorporating components aimed at mass reduction, parts
consolidation to reduce assembly costs and more efficient recycling. The automaker's need to improve overall fuel economy
in vehicles has led to the trend toward minimising vehicle weight. The use of performance materials such as high strength
steel and aluminium is on the rise and heavier traditional materials, such as steel and iron, are being replaced whenever
possible.
According to Bosch, steel thicknesses range from 0.6mm to 3.0mm, and most parts range from 0.75mm to 1.0mm thick.
Due to the mechanical properties of steel with regard to rigidity, strength, economy and ductility, alternative materials for
the vehicle body structure are not yet available. Bosch points out that HSLA (high strength low alloy) steel is used for high-
stress structural components. The resulting high strength of these components allows their thickness to be reduced.
Meanwhile, Honda Motor has developed a technology for the continuous welding of the dissimilar metals of steel and
aluminium and applied it for the first time in the world to the subframe of a mass-production vehicle, a key component of a
vehicle body frame. Honda is applying this technology to the North American version of the 2013 Accord and says it will
expand the application sequentially to other models. The automaker claims that this technology generates a new and stable
metallic bonding between steel and aluminium by moving a rotating tool on the top of the aluminium which is lapped over
the steel with high pressure. As a result, the welding strength becomes equal to or beyond conventional Metal Inert Gas
(MIG) welding.
In March 2013, Nissan Motor revealed its plan to expand the use of advanced high tensile strength steel (AHSS) in up to
25% of the vehicle parts (measured by weight) installed in its new production models. Nissan will make use of advanced
high tensile strength steel starting in 2017 as one of its initiatives to help reduce vehicle weight. Nissan has developed 1.2
gigapascal (GPa) ultra-high tensile strength steel with high formability and has employed it in the new Infiniti Q50, which
goes on sale in North America in 2013. Prior to the development of 1.2GPa ultra high strength steel, it had been difficult to
use high tensile steels for vehicle parts with highly-complex shapes. Nissan continues to be the only auto manufacturer
using 1.2 GPa Ultra high tensile strength steel with high formability. With the active adoption of 1.2 GPa ultra-high strength
steel, which is one grade among several types of advanced high tensile strength steels, Nissan will increase the adoption
rate of AHSS as far as 25% of the gross weight of the parts installed per vehicle. This effort will begin in 2017 and aims to
reduce the weight of Nissan's vehicles by 15% with corresponding body structure rationalisation. Under the Nissan Green
Programme 2016, Nissan's mid-term environmental plan, the company is aiming for a 35% improvement in fuel economy
compared with 2005 on a corporate average for all Nissan vehicles by the end of fiscal 2016. To that end, the extensive use
of advanced high tensile strength steels, including the new 1.2GPa ultra high tensile steel, will contribute to reduced vehicle
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weight and better fuel economy.
Applications
Bumpers
In 2011, Mazda Motor, in collaboration with Sumitomo Metal Industries and Aisin Takaoka, became the first automaker to
develop vehicle components using 1,800 MPa ultra-high tensile steel. The super strength steel, used to fabricate bumper
beams, debuted in the Mazda CX-5 crossover SUV launched in 2012. Mazda's new production technology uses 1,800 MPa
ultra-high tensile steel to fabricate bumper beams, which fit inside the front and rear bumpers and mitigate damage in the
event of a collision. The bumper bars are claimed to be 20 percent stronger and 4.8 kgs lighter than previous versions.
Fuel tanks
The Strategic Alliance for Steel Fuel Tanks (SASFT) along with the Auto/Steel Partnership and the US Automotive Materials
Partnership have developed a methodology for producing lightweight sealed steel fuel tanks with 30 to 40 percent mass
reductions when compared with current–generation sealed steel tanks.
Funded by the US Department of Energy, the project demonstrates that manufacturing approaches can be used with thinner
high-strength steel and advanced high-strength steel (AHSS) to reduce mass and meet performance requirements
associated with sealed systems, including structural integrity, fatigue, corrosion, durability and crash integrity.
Seats
A US-based technology partnership between the United States Automotive Materials Partnership LLC United States Automotive Materials Partnership LLC and
Auto/Steel PartnershipAuto/Steel Partnership using structural optimisation techniques within a car’s passenger compartment has shown “good
potential” for no-compromise vehicle light-weighting. As part of the ‘Future Generation Passenger Compartment –
Validation’ project, the partners used computer modeling to validate a potential mass savings of 15 to 20 percent in a
preproduction sedan when advanced high-strength steels and design variations were selectively applied. By applying new
load paths (in this case, transverse tubes that directly absorb side impact forces) within the front seat, the results showed
that using high-strength steel lowered mass and weight considerably without compromising the passenger compartment’s
structural integrity or crashworthiness. The next step for the team involves sharing the results within their companies,
allowing each USCAR OEM to determine if, how and when they would use the design process for production.
Faurecia Faurecia is working with Rhodia to develop lightweight automotive seat structural components using polyamide-based
high-performance engineering plastics. Faurecia and Rhodia have worked together since November 2009 and ratified their
cooperation with the signature of a joint development agreement in February 2011. The main aim of this agreement is to
develop a range of seat cushion components using Rhodia’s Technyl SI, an impact-modified polyamide grade. The resulting
plastic seat cushion structural components are expected to be 20 percent lighter than conventional steel parts. The seat
cushion structural components jointly designed by Faurecia and Rhodia are expected to enter series production expected inCopyright 2013, just-auto Generated on 11 April 2013 71
2014.
Wheels
During the 1980s, with the growing emphasis on fuel economy and the need to reduce vehicle weight, vehicle makers
turned to alloy wheels in preference to steel. Hurt by the loss, steelmakers enlisted the help of wheel manufacturers and
OEMs and launched a campaign to create new wheel styling and explore the use of new steels. Using bright materials like
stainless steel that attach predominantly to the wheel and modifying disc and rim designs to enhance styling, wheel makers
managed to satisfy consumers’ desire for a decoratively styled wheel.
Among the reasons for the comeback of steel wheels are high-strength steels and new designs that offer large ventilation
openings that mimic the thin-spoke appearance of some alloy wheels. More specifically, the use of high-strength steel, plus
high-ventilation area wheels design, increases steel wheel market opportunities. Lighter-weight, high-strength steel has
opened up an increased opportunity to mimic the thin-spoke appearance of some alloy wheels. In addition, the use of high-
strength steel has drastically reduced the weight penalty normally associated with steel wheels.
Jim Cran, project manager of the American Iron and Steel Institute’s Wheel Task Force, told us: “Since 2005, the Big Three
have significantly reduced the percentage of aluminium wheels they use. Cost was a huge driver. Also, the Big Three have
recognised people want good looking wheels. Material is immaterial. The large vent area steel wheel has received excellent
acceptance. It gives a styling that is competitive with aluminium and cost savings over aluminium. The use of permanently-
bonded facia has also been a factor. The same base steel wheel can be used on different makes and models. Only the fascia
needs to be changed. Significant development and tooling savings result in lower-cost steel wheels. Yet another factor is the
fact that the ratio of car to light truck sales is increasing. The trend to a higher percentage of cars means a higher
percentage of steel wheels because the use of aluminium wheels is greater on light trucks than on cars.”
In addition to lower weight, there are a number of other benefits of steel wheels over aluminium. Along with lower costs,
steel wheels offer better pothole resistance and improved corrosion resistance in the bead-seat area.
The new Smart forvision features thermoplastic wheel rims which have, claims the vehicle maker, been tested for mass
production. The all-plastic wheel rim is over 30% lighter than a standard production aluminium wheel. The plastic rim
weighs six kilos and is made of the new specialty polyamide Ultramid Structure from BASF. This results in reduction in the
vehicle's weight by a total of 12 kilos.
Other materials
Alternative material to nylon 12 resinSolvay Specialty Polymers is providing alternative material options to automotive tyre suppliers. More specifically, Solvay isoffering to the market Amodel polyphthalamide (PPA) and Ixef polyarylamide (PARA) for key fuel line connectors and glycolconnectors which were previously moulded of nylon 12 resin. Amodel PPA is a semi-aromatic polyamide with greaterthermal capabilities, better chemical resistance, and less sensitivity to moisture than conventional polyamides. Other keyattributes are higher strength and stiffness at elevated temperatures and better retention of mechanical properties in highhumidity. Amodel PPA has been used in automotive, electronic, plumbing, and industrial applications for over 20 years.
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Interior films from 3M
Visteon is in the process of showcasing its so-called Growth Market Car which features a number of unique styling elements
designed using 3M Interior Trim Films (ITF). 3M says its ITF brings the “luxury look and feel” of materials to the concept car's
interior door handles and the trim spear of the passenger side of the instrument panel, adding “authenticity and richness
without the extra cost."
Recycling
Batteries
GS Yuasa, Mitsubishi Motors GS Yuasa, Mitsubishi Motors and two other companies have developed a method to recycle electric vehicle lithium-ion
batteries. The system uses a solar battery to store power it generates in used lithium ion battery for rapid refueling of i-
MiEVs.
Johnson Controls Johnson Controls operates a battery recycling facility in Florence, South Carolina. The US$150m facility is operated by
JCI's power solutions business The facility was the first facility of its kind to receive an air permit in the US in nearly 20
years. Johnson Controls has also invested some US$70m in its automotive battery recycling centre in Cienega de Flores,
Nuevo Leon, Mexico.
Battery firm AxeonAxeon is one of six British companies to receive a share of nearly GBP500,000 funding from the Technology
Strategy Board (TSB) for feasibility studies into the recycling and re-use of batteries for hybrid and electric vehicles. In
addition to researching the recycling process, the project will look at how to determine end-of-life, which is still a major
issue with automotive batteries for both manufacturers and consumers. The project ultimately aims to develop a UK battery
recycling industry for end-of-life automotive batteries.
GMGM and ABBABB have demonstrated an energy storage system that combines electric vehicle battery technology and a grid-
tied electric power inverter. The system, says GM, could store electricity from the grid during times of low usage to be used
during periods of peak demand. The battery packs could also be used as back-up power sources during outages and
brownouts.
In October 2011, Toyota Motor Europe Toyota Motor Europe (TME) signed a three-year framework agreement (2011-2014) with the Société
Nouvelle d'Affinage des Métaux (SNAM), based in France, for the European-wide take back and sustainable recycling of high
voltage industrial nickel-metal hydride (NiMH) batteries. Under the terms of the deal, SNAM will ensure that the process
for the treatment of NiMH batteries through the optimal recycling channels will ensure the maximum output on secondary
raw materials. The agreement between TME and SNAM also ensures recovered NiMH batteries can be taken back from any
of Toyota's European operations, including the European head office in Belgium, any of the nine manufacturing facilities in
seven countries, 30 national marketing and sales companies, 3,000 dealer and any authorised end-of-life vehicle treatment
operator.
Ninety eight percent of automotive aftermarket companies, including auto repair shops, manufacturers, distributors,
retailers and jobbers, according to a study by the Automotive Aftermarket Industry AssociationAutomotive Aftermarket Industry Association (AAIA) are recycling
Copyright 2013, just-auto Generated on 11 April 2013 73
car batteries. As a result of these efforts, an estimated 65m automotive batteries were recycled in 2010, equal to 1.5 billion
pounds of lead, according to AAIA's Aftermarket Factbook. More than 95% of an automotive battery can be recycled. The
lead, plastic, acid and sulphuric acid found in batteries are reclaimed and reused in the manufacturing of new batteries.The
lead is cleaned and melted and used in the production of new lead plates and other parts for new batteries. The plastic is
cleaned and melted into pellets used to manufacturer new battery cases. Old battery acid can be neutralised into water,
which after treatment, cleaning and testing, can be released into the public sewer system, or it can be converted into
sodium sulphate and used in laundry detergent, glass and textiles.In addition to recycling batteries, automotive aftermarket
companies recycle tyres, used oil and oil filters, parts cleaning solvents, scrap metal, plastics, cardboard and paper, a/c
refrigerant, dunnage and wood pallets.
Nissan North America, ABB, 4R Energy Nissan North America, ABB, 4R Energy and Sumitomo Corporation of AmericaSumitomo Corporation of America have formed a partnership to
evaluate the reuse of lithium-ion battery packs that power the Nissan Leaf. The purpose is to evaluate and test the
residential and commercial applications of energy storage systems or back-up power sources using lithium-ion battery packs
reclaimed from electric vehicles after use. Energy storage systems can store power from the grid during times of low usage
and feed that electricity back into the grid during periods of peak demand, increasing grid performance and providing back-
up power during outages. The team plans to develop a Leaf battery storage prototype with a capacity of at least 50 kilowatt
hours, enough to supply 30 average homes with electricity for one hour.
Bumpers
Plastic Omnium has developed a bumper using recycled plastic. The patented process uses polyolefin collected through
recycling channels (mainly auto industry manufacturing waste and crushed parts) to produce a recycled plastic that, PO
claims, delivers the same technical performance in terms of impact resistance and paint adhesion as parts made with new
plastic.
Since 2006, regulations have required that 85 percent of a vehicle’s weight be reusuable as recycled material or energy, a
figure that is expected to rise to 95 percent in 2015.
Glazing
As far as automotive glazing recycling is concerned, the main issue in Europe centres on the removal of glass from vehicles.
The End-of-Life Vehicle (ELV) Directive has set standards for the amount of materials in vehicles which must be reused or
recycled. Although glass makers are working to comply with this directive, some automotive glass has limitations in terms of
recycling. This is due to additional features, such as heating elements, coatings, adhesives or metal clips that are added to
glass.
Saint-Gobain Sekurit says it is involved in R&D to improve recycling of automotive glass, using modules or sub-modules that
are easily dismantled to provide a simpler, less costly and more environmentally-friendly method of recycling at the end of
the product’s life.
For background information, the European Directive on ELV aims to prevent waste from vehicles and to promote reuse and
recycling as well as other forms of recovery of vehicles and their components. The scope of the Directive covers end-of-life
vehicles and their components and materials. Vehicle manufacturers, material and equipment suppliers shall reduce the useCopyright 2013, just-auto Generated on 11 April 2013 74
of hazardous substances as far as possible. The Directive requires that materials and components used in vehicle
manufacture from 1 July 2003 shall not contain lead, mercury, cadmium or hexavalent chromium. From 1 January 2006, the
reuse and recovery was increased to a minimum 85% (average weight per vehicle and year) and reuse and recycling
increased to 80%. From 1 January 2015, the reuse and recovery shall be increased to 95% and reuse and recycling to 85%.
All car types approved from 2005 should be reusable and/or recyclable to a minimum of 85% and recoverable to a minimum
of 95% by weight per vehicle.
Interiors
Ford is using recycled cottons in the interior of the Focus as part of carpet backing and sound absorption material. Cotton
from post-consumer, recycled blue jeans is used in areas such as carpet backing and sound-absorption materials for interior
quietness. Using environmentally friendly materials, including recycled clothing, is one part of Ford’s overall green strategy.
“Ford is continually looking for greener alternatives,” said Carrie Majeske, product sustainability manager. “One of our key
goals is to use more recycled or renewable materials without compromising performance or durability. Recycled content is a
way to divert waste from landfills and reduce the impact of mining virgin material.”
Ford’s “reduce, reuse and recycle” commitment is part of the company’s broader global sustainability strategy to reduce its
environmental footprint while at the same time accelerating the development of advanced, fuel-efficient vehicle
technologies around the world.
Over the past several years, Ford has concentrated on increasing the use of non-metal recycled and bio-based materials,
including soy foam seat cushions, recycled resins for underbody systems, recycled yarns on seat covers and natural-fibre
plastic for interior components.
“The good news is these jeans didn’t end up in a landfill, nor did we use the water, fertilizer and land to grow virgin cotton,”
Majeske said. “It’s an alternative that our customers can appreciate, it’s cost effective, and it’s better for our planet. These
are the kinds of sustainable solutions we are looking for in all our vehicles.”
The amount of post-consumer cotton from blue jeans used in a vehicle comes out to roughly two pairs of average-sized
American jeans, based on pounds of cotton used per yard of denim and the yards of denim used to make a pair of jeans.
“Great fuel economy is our first priority for reducing the vehicle’s impact on the environment,” said Majeske. “As we deliver
that, we also seek to use materials inside a vehicle that reduce the environmental impact as well. The use of recycled
clothing is one step, but what else are people discarding that could be used in our vehicles? Ford is determined to find out.”
Ford is also using 25 20-ounce plastic bottles to make the carpeting in every new Ford Escape utility vehicle it builds. It's the
first time Ford has used this type of carpeting in an SUV. Ford’s engineers point out that adding more recycled bottles can
help prolong the life of the carpet and prevent from forming holes from wear down.
More specifically, Ford's Focus Electric will feature seat fabric made of recycled material that includes the equivalent of
more than 20 plastic bottles per car. The fibre - called REPREVE - is made from a hybrid blend of recycled materials and
manufactured by Unifi. Unifi says 22 plastic, 16-ounce water bottles are used in the seat fabric of a single Focus Electric.
The figure is based on the amount of REPREVE branded fibre used in the production of fabric in each vehicle. Ford is the first
automaker to use REPREVE branded fibre in its seat fabric.
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Tyres
Ford makes gaskets and seals from recycled tyres
Ford is working with Recycled Polymeric Materials (RPM) to deliver gaskets and seals made from recycled tyres and bio-
renewable content such as soy.
Ford says that more 2.2m pounds of rubber from recycled tyres have been made into seals and gaskets and some 210,000
used tyres have been recycled. Some 150,000 pounds of soy has been used to create the materials.
The gaskets and seals are already featured on a number of Ford models, including F-150, Escape, Mustang, Focus and Fiesta.
The gaskets and seals are derived from 25 percent post-consumer particulate from recycled tyres and 17 percent bio-
renewable content from soy.
Ford also says that the seals offer weight savings, with more than 1,675 tons of weight removed from Ford vehicles on the
road.
Ford vehicles that feature the sustainable seals and gaskets include:
Ford Escape
Ford F-150
Ford F-250
Ford F-350
Ford Fiesta
Ford Flex
Ford Focus
Ford Mustang
Ford Taurus
Ford Transit Connect
Lincoln MKS
Ford says that over the past several years it has concentrated on increasing the use of recycled plastics and bio-based
materials whenever possible. Examples include soy foam seat cushions, wheat straw-filled plastic, recycled resins for
underbody systems, recycled yarns on seat covers and natural-fibre plastic for interior components.
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Motor oil
Universal Lubricants is promoting its green motor oil – Eco Ultra, an American Petroleum Institute (API) certified motor oil
that has one of the highest percentages of recycled oil content. Universal Lubricants collects, refines blends and re-
distributes its own green motor oil. Eco Ultra is made at the company's advanced re-refinery in the US.
"Using re-refined (or recycled) oil cuts fossil fuel use, lowers greenhouse gas emissions and reduces harmful environmental
impacts on our Nation's waterways. Eco Ultra provides American drivers the performance and reliability they expect in a
high quality motor oil while at the same time having one of the highest percentages of recycled oil content," said chief
executive officer of Universal Lubricants, John Wesley.
Universal Lubricants collects used oil from the government and private business such as auto parts stores, dealerships,
service stations, and oil change centres across the US. The company then transports that oil to a re-refinery located
in Wichita, Kansas, where it undergoes hydro-treating process to remove all of the water, fuel and solvents as well as
metals, asphalt flux and other heavy contaminants.
The purified high quality Grade II base stock oil is then blended with a synthetic formula and additives to make API certified
Eco Ultra products. That oil is then collected again by the company and put back through its closed loop process.
Plastics
Recycling initiatives at Renault have boosted the use of recycled plastics in new cars and cut purchasing costs on some
parts, but have yet to bring major cost savings for the French carmaker.
“If we order a piece in recycled plastic, we systematically insist on paying less than if it was made from virgin plastic,” said
Fabrice Abraham, Renault’s recycling engineering manager. “Aside from that purchasing policy, it’s hard to put a hard
number on cost savings. The end-of-life recycling initiative has really been more of a laboratory for eco-conception and
meeting other environmental objectives,” Abraham said.
Renault became a major player in the French recycling sector in 2008, when it launched an EUR100m joint venture with
Sita France, the recycling arm of French environmental services giant Suez, to develop end-of-life vehicle recycling
programs. The JV has since taken control of Indra Investissement, which manages 350 vehicle dismantlers nationwide.
Indra’s dismantler network is spearheading Renault’s bid to comply with European Union rules that will force carmakers to
demonstrate that their new vehicles are designed to be at least 85 percent recyclable or reusable and 95 percent
recoverable from 2015.
Renault’s third-generation Megane hatchback, which launched in late-2008, was the first model specifically designed to
meet certifiable recycling standards, according to Alice de Brauer, Renault’s director of environmental planning.
“Life-cycle analysis has become a major element in not only the environmental discussion, but the product planning cycle as
well,” de Brauer said.
After observing recycling processes at dismantler sites, Renault has added easily-accessible siphons into fuel tank and
radiator designs, to allow simpler drainage and collection of fluids. “Everything we do on the eco-design side should simplify
operations for dismantlers,” Abraham added.Copyright 2013, just-auto Generated on 11 April 2013 77
[210][210]
Such research has also led to design changes in many plastic parts at Renault, to reduce mixing materials that are
incompatible in the recycling process.
Beyond ensuring recyclability, the French carmaker says its end-of-life recycling initiative should help it meet goals to
include 20 percent of recycled plastic in all new vehicles by 2015.
The Scenic people mover, which is built on the Megane platform and shares many of its parts and components, is Renault’s
current champion, and a case in point regarding recycling. The Scenic contains 34 kilograms of recycled plastics,
representing about 14 percent of total plastics in the vehicle. It is a dramatic improvement from the 8 kg of recycled plastics
used in 1999, but still below the 50 kg ceiling Renault aims to hit during 2015.
Cars on Renault’s low-cost Logan platform average about 7 percent recycled plastic, while the Clio compact and Twingo
minicar weigh in with 11 percent and 9 percent recycled plastics respectively.
All told, Renault incorporated 27,000 tonnes of recycled plastic into its new cars in 2009, a figure slated to rise dramatically
in the coming decade, de Brauer said.
While recycled plastic was once reserved for invisible under-pinnings such as wheel arch liners, it is now used in everything
from dashboards to bumpers and interior trim pieces. “We’re making rapid progress, and no longer just using recycling
plastics in parts that you don’t see, but those that are apparent as well,” Abraham said.
Working with dismantlers has allowed Renault to improve the quality of recycled plastics - principally the use of colour - and
boost uptake, but it has also highlighted long-term challenges for meeting recyclability targets, notably for glass.
“Everyone in the recycling business obviously wants to make money, but that is really hard given the high logistics costs
associated with glass, not to mention the extremely complicated manufacture process,” Abraham said.
Renault is working with recycling industry partners on potential alternative uses for recycled glass from end-of-life vehicles,
including incorporation into building insulation or paints. “Figuring out glass recycling will be the key to meeting the
European targets,” he concluded.
Steel
The use of steel for an increasing range of components is helping vehicle makers to improve vehicle recyclability and meet
the demands of legislation. The End of Life Vehicle Directive states that 85 percent of the mass of any new car sold in the
EU must be recycled or reused. A vehicle engineering study by Corus on designs for a clutch pedal in aluminium, plastic and
steel demonstrates that improving recyclability need not have an adverse effect on cost or performance.
The following table sets out a comparison of the clutch pedal using different materials.
Evaluation of a clutch pedalEvaluation of a clutch pedal
Design Advantages Disadvantages Piececost
(EUR)
Mass(kg)
Steelfabrication
Recyclable, low parts, cost, stiff,robust
High mass, moderate toolingcost, poor NVH 2.81 0.58
Plasticinjection Low mass, good for complex shapes, Poor recycling, high parts cost, 3.51 0.3
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[211]
[213][213]
[214]
Source(s)Source(s) Corus
Evaluation-of-a-clutch-pedal_13612760122392.csv
The following table sets out the amount of CO2 emissions saved by modifying certain automotive technologies.
Cost of CO2 savingCost of CO2 saving
Source(s)Source(s) VAG, IEA 2005, TNO/Ricardo, PSA, Ford, Corus Research
Cost-of-CO2-saving_13612760092391.csv
Waste packaging
Federal Mogul has developed a novel product that helps General Motors eliminate noise in a vehicle’s cabin using recycled
waste packaging and other by-products normally discarded at a vehicle manufacturing plant. Federal Mogul’s so-called
QuietShield GRN’s (Green Non-woven) first application was on the 2010 Buick LaCrosse luxury sedan. Cardboard packaging
used by manufacturers is then recycled into QuietShield GRN and, in this case, used as acoustical padding in the LaCrosse’s
headliner. The recyclable by-products collected at the vehicle manufacturing plant are shredded, combined with other
recycled materials, formed into a web and bonded in a manufacturing process developed by the supplier. Federal Mogul
claims the padding can be used by vehiclemakers and other industries to fabricate linings and sound deadening padding in
headrests, door and kick panels and boot liners to abate noise entering the vehicle cabin. Federal-Mogul is also supplying its
QuietShield GRN for the Buick Verano.
injectionmoulding good NVH low stiffness, not robust 3.51 0.3
Steelpressing Recyclable, low parts cost, robust, stiff High mass, high tooling cost,
not suited to complex shapes 2.2 0.39
Aluminiumalloy
Recyclable, low mass, low toolingcost, robust, good for complex shapes
High parts cost, poor Noise,Vibration and Harshness (NVH) 4.2 0.36
Modification % CO2 saving Cost/car (EUR) Cost/% gain (EUR)
Gearing/ECU tune 6 10 1.6Low rolling resistance tyres 5 40 8Aero tweaks 2 50 25Low friction lubricants 0.7 30 40Dual circuit cooling 0.5 25 50Microhybrid (stop/start) 3 200 66Efficient alternator 0.5 35 70Heat storage system 0.5 60 120Aero design (10% lower Cd) 4 600 150Electric water pump 0.5 80 160Mild hybrid (diesel) 10 2000 200Automated 6-speed manual 4 1000 250Full hybrid (e.g. Prius) 22 6000 270Aluminium bonnet 0.25 75 300
Modification % CO2 saving Cost/car (EUR) Cost/% gain (EUR)
Copyright 2013, just-auto Generated on 11 April 2013 79
Emerging markets
India
Minda Industries has formed a joint venture with Kyoraku Company and Nagase & Company to manufacture blow moulded
plastic products. The partners hold shares in the joint venture at ratios of 74, 16 and 10 percent, respectively. Minda makes
automotive components and supplies OEMs. The group recently opened a design centre in Taiwan.
Forecasts
This section sets out our estimates and forecasts of the use of the main materials used in vehicle manufacture, namely
steel, iron, aluminium, plastics and glass.
For each material, our forecasts set out the percentage of total kerb weight of a medium-sized passenger car, e.g. VW Golf,
Ford Focus. Today, such cars in Europe weigh in at around 1,500 kg (or 1.5 metric tons) compared to about 800 kg in the
1970s. In North America, an average sized passenger cars weighs approximately 2,000 kg. Smaller European cars, such as
the Fiat Punto currently weigh about 1000 kg whereas larger cars, such as a 4x4, typically weigh approximately 3,000 kg.
Despite its impact on fuel consumption, the average mass of vehicles has increased over the past 40 years. For example, a
Ford Escort weighed in at around 875 pounds in 1974. By 1998, a Ford Focus weighed approximately 1,100 pounds.
According to the European Aluminium Association, the weight increase across all vehicle models is due to more stringent
legislative requirements and changing customer demands (i.e. growing vehicle size, extra comfort and safety features) and
that, in turn has caused an increase in weight of other components, such as brakes, engines and transmissions.
Steel
The use of plastics, aluminium, magnesium and different grades of steel are all under scrutiny by the vehicle makers in a bid
to optimise factors. While the use of plastics in vehicles has significantly increased over the last five years, the steel industry
has also proved flexible by reducing the weight of components without sacrificing strength.
The automaker's need to improve overall fuel economy in vehicles has led to the trend toward minimising vehicle weight.
The use of performance materials such as high strength steel and aluminium is on the rise and heavier traditional materials,
such as steel and iron, are being replaced whenever possible.
Mild steels is the most common material used in vehicle manufacture. Despite the advances made by aluminium and
polymers, steel offers good value in mass production and simpler production processes than its rivals.
Meanwhile, high strength steels are used in a variety of applications, including floors, roof supports, side pillars and doors.
The following table sets out steel as a percentage of total kerb weight of a medium-sized passenger car.
Copyright 2013, just-auto Generated on 11 April 2013 80
[216][216]
[217]
[219][219]
Steel as a percentage of total kerb weight of medium-sized passengerSteel as a percentage of total kerb weight of medium-sized passengercars assembled in all major car producing regions, 2007-2027cars assembled in all major car producing regions, 2007-2027
Source(s)Source(s) just-auto
Steel-as-a-percentage-of-total-kerb-weig_136396525758032.csv
Iron
The use of plastics, aluminium, magnesium and different grades of steel are all under scrutiny by the vehicle makers in a bid
to optimise factors. While the use of these materials in vehicles has significantly increased over the last five years, the use
of iron is decreasing.
For example, some vehicle makers are switching from traditional iron blocks for engines to aluminium construction. Although
not as durable as iron, aluminium is lighter thereby boosting fuel economy.
The following table sets out iron as a percentage of total kerb weight of a medium-sized passenger car.
Iron as a percentage of total kerb weight of medium-sized passenger carsIron as a percentage of total kerb weight of medium-sized passenger carsassembled in all major car producing regions, 2007-2027assembled in all major car producing regions, 2007-2027
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
NorthAmerica 48.76 48.51 48.27 48.03 47.79 47.6 47.36 47.13 46.89 46.66 46.4
Mercosur 49.45 49.2 48.96 48.71 48.47 48.3 48.06 47.82 47.58 47.34 47.1WesternEurope 49.25 49.01 48.76 48.52 48.27 48.1 47.86 47.62 47.38 47.15 46.9
CentralEurope 48.76 48.51 48.27 48.03 47.79 47.4 47.16 46.93 46.69 46.46 46.2
Russia 48.85 48.61 48.37 48.13 47.88 47.5 47.26 47.03 46.79 46.56 46.3Japan 48.56 48.31 48.07 47.83 47.59 47.3 47.06 46.83 46.59 46.36 46.1China 48.06 47.82 47.58 47.34 47.1 46.8 46.57 46.33 46.1 45.87 45.6India 47.86 47.62 47.38 47.15 46.91 46.6 46.37 46.14 45.9 45.67 45.5Korea 48.76 48.51 48.27 48.03 47.79 47.5 47.26 47.03 46.79 46.56 46.3Thailand 49.25 49.01 48.76 48.52 48.27 47.9 47.66 47.42 47.19 46.95 46.7Other 48.06 47.82 47.58 47.34 47.1 46.7 46.47 46.23 46 45.77 45.5
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
NorthAmerica 8.96 8.91 8.87 8.82 8.78 8.7 8.66 8.61 8.57 8.53 8.5
Mercosur 9.15 9.11 9.06 9.02 8.97 8.9 8.86 8.81 8.77 8.72 8.7WesternEurope 8.56 8.51 8.47 8.43 8.39 8.3 8.26 8.22 8.18 8.14 8.1
CentralEurope 8.46 8.42 8.37 8.33 8.29 8.2 8.16 8.12 8.08 8.04 8.0
Russia 8.16 8.12 8.08 8.04 8 7.9 7.86 7.82 7.78 7.74 7.7Japan 8.36 8.32 8.27 8.23 8.19 8.1 8.06 8.02 7.98 7.94 7.9China 8.36 8.32 8.27 8.23 8.19 8.1 8.06 8.02 7.98 7.94 7.9India 8.56 8.51 8.47 8.43 8.39 8.3 8.26 8.22 8.18 8.14 8.1Korea 8.26 8.22 8.18 8.14 8.09 8 7.96 7.92 7.88 7.84 7.8Thailand 8.76 8.71 8.67 8.63 8.58 8.5 8.46 8.42 8.37 8.33 8.3Other 9.05 9.01 8.96 8.92 8.87 8.8 8.76 8.71 8.67 8.63 8.6
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
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[220]
[222]
[223][223]
Source(s)Source(s) just-auto
Iron-as-a-percentage-of-total-kerb-weigh_135575720458033.csv
Aluminium
Although aluminium content in cars is increasing, albeit slowly, we should expect to see significant inroads emerging over
the next few years. The automotive market has lately become the largest and fastest-growing single market sector for
aluminium producers.
A study, commissioned by the US-based Aluminium Association, showed that North American use of automotive aluminium
is at an all-time high, averaging 8.6% of vehicle kerb weight[1] in 2009 calendar year vehicles, up from just 2% in 1970
and 5.1% in 1990. The integration of aluminium in cars and light trucks is projected to be nearly 11% of kerb weight by
2020.
On a worldwide basis, the amount of aluminium content for light vehicles is predicted to continue at a rate of 4 - 5 pounds
per vehicle, per year, and approach 300 pounds per vehicle worldwide in 2020.
“The data demonstrate that automakers in North America and around the globe continue to recognise the value of automotive
aluminium,” said Buddy Stemple, chairman of the Aluminium Association’s auto and light truck group. “As automakers seek
to innovate and differentiate themselves with more fuel-efficient cars and trucks with a reduced carbon footprint, the time to use
advanced materials like aluminium is now – and this study shows that automakers agree.”
On a component basis, the study cites engine blocks and steering knuckles with the largest increase in growth over the last
three years; with penetration of aluminium blocks reaching nearly 70% – the largest driver of aluminium growth in this
decade. In addition, more than 22% of vehicles currently made in the US have aluminium bonnets (hoods), an all-time
record. “We’re seeing continued growth of automotive aluminium because of the relevant advantages it offers, such as improved
fuel economy and vehicle safety,” said Stemple. “In fact, hybrid and diesel vehicles when paired with aluminium can actually pay
consumers back faster than if those vehicles were made of heavier steel.”
On balance, the following tables sets out our estimates and forecasts of the use of aluminium as a percentage of the total
kerb weight of a medium-sized passenger car across a number of major car-producing regions and countries.
Over the past decade, aluminium content has experienced steady growth in light vehicle applications in these regions. Long-
term growth rates remain in line with the significant growth rates of the late 1970s to early 1990s, despite the shift to
smaller vehicles.
As the future of the global automotive industry quickly shifts to more fuel-efficient products, vehicles around the world will
be manufactured with a variety of solutions and powertrain improvements.
The following table sets out aluminium as a percentage of total kerb weight of a medium-sized passenger car.
Aluminium as a percentage of total kerb weight of medium-sizedAluminium as a percentage of total kerb weight of medium-sizedpassenger cars assembled in all major car producing regions, 2007-2027passenger cars assembled in all major car producing regions, 2007-2027Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
North 7.7 7.8 8 8.1 8.3 8.5 8.6 8.8 9 9.1 9.3
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
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[224]
[226][226]
Source(s)Source(s) just-auto
Aluminium-as-a-percentage-of-total-kerb-_136396525058030.csv
[1] Kerb weight is the weight of a car with no passengers or luggage but with a full fuel tank.
Plastics
The trends toward the increased use of plastics in exterior and structural/functional/ powertrain components have been
driven by innovations in material, moulding and painting technologies, which have improved the performance and
appearance of moulded plastic components as well as lowering their costs. The design freedom that plastic offers is also key
to its increased use. Not only does plastic allow for the manufacture of products that cannot be manufactured with other
materials, but plastic makes it possible to combine several parts, saving weight and cost. Additionally, recently introduced
plastics that can withstand the hot, corrosive environment of the engine compartment are becoming more prevalent.
The increased use of plastics reduces the weight of vehicles and consequently emissions. The weight reductions brought
about through the increased use of plastics has also offset the extra weight brought about by improved safety features such
as airbags. The British Plastics Federation points out that using 100kg of plastics in a car can replace between 200-300kg of
traditional materials. Over the average lifespan of a vehicle every 100kg of plastics will reduce fuel consumption of the
vehicle by 750 litres.
The following table sets out plastics as a percentage of total kerb weight of a medium-sized passenger car.
Plastics as a percentage of total kerb weight of medium-sized passengerPlastics as a percentage of total kerb weight of medium-sized passengercars assembled in all major car producing regions, 2007-2027cars assembled in all major car producing regions, 2007-2027
America 7.7 7.8 8 8.1 8.3 8.5 8.6 8.8 9 9.1 9.3
Mercosur 6.1 6.2 6.4 6.5 6.6 6.9 7 7.2 7.3 7.5 7.6WesternEurope 7.4 7.6 7.7 7.9 8.1 8.3 8.4 8.6 8.8 8.9 9.1
CentralEurope 7.3 7.5 7.6 7.8 7.9 8.2 8.3 8.5 8.6 8.8 9.0
Russia 6 6.1 6.3 6.4 6.5 6.7 6.8 6.9 7.1 7.2 7.3Japan 7.4 7.6 7.7 7.9 8.1 8.3 8.4 8.6 8.8 8.9 9.1China 7.2 7.4 7.5 7.7 7.8 8.1 8.2 8.4 8.5 8.7 8.9India 6.2 6.3 6.5 6.6 6.7 7 7.1 7.2 7.4 7.5 7.7Korea 6.5 6.7 6.8 6.9 7.1 7.3 7.4 7.5 7.7 7.8 8.0Thailand 5.9 6 6.2 6.3 6.4 6.6 6.7 6.8 7 7.1 7.2Other 5.9 6 6.2 6.3 6.4 6.6 6.7 6.8 7 7.1 7.2
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
NorthAmerica 8.2 8.3 8.5 8.6 8.7 9 9.1 9.2 9.4 9.5 9.6
Mercosur 6.1 6.2 6.3 6.4 6.5 6.7 6.7 6.9 7 7.1 7.2WesternEurope 7.4 7.5 7.6 7.7 7.9 8.1 8.2 8.3 8.4 8.5 8.7
CentralEurope 7.2 7.3 7.4 7.5 7.6 7.9 8 8.1 8.2 8.3 8.5
Russia 7.1 7.2 7.3 7.4 7.5 7.8 7.9 8 8.1 8.2 8.3Japan 7.9 8 8.2 8.3 8.4 8.6 8.7 8.8 8.9 9.1 9.2
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
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Source(s)Source(s) just-auto
Plastics-as-a-percentage-of-total-kerb-w_136396525458031.csv
Glass
In observing trends in the auto glazing industry, glass makers report how the glazing area in vehicles has increased by about
25% since the early 1990s. Higher and wider windshields have led to the quantity of glass used in vehicle manufacture to
gradually increase. A mid-range saloon carries around 100lb of glass today, compared to around 85lb in 1990. That’s about
3% of the total kerb weight of the average car. More recently, the trend is toward larger, more complex windshields and
bigger sunroofs. The surface glazing of certain Peugeot cars, for example, has increased over the years; the Peugeot 304 had
a surface glazing area of some 2.24-m², rising to 2.82-m² for the Peugeot 305, 2.96-m² for the Peugeot 306, 3.57-m² for the
Peugeot 307 and 5.34-m² for the Peugeot 307 SW.
The following table sets out glass as a percentage of total kerb weight of a medium-sized passenger car.
Glass as a percentage of total kerb weight of medium-sized passengerGlass as a percentage of total kerb weight of medium-sized passengercars assembled in all major car producing regions, 2007-2027cars assembled in all major car producing regions, 2007-2027
Source(s)Source(s) just-auto
Glass-as-a-percentage-of-total-kerb-weig_135575720758034.csv
Other materials
China 6.9 7 7.1 7.2 7.3 7.5 7.6 7.7 7.8 7.9 8.0India 7.3 7.4 7.5 7.6 7.8 8 8.1 8.2 8.3 8.4 8.6Korea 7.5 7.6 7.7 7.9 8 8.2 8.3 8.4 8.5 8.7 8.8Thailand 7.4 7.5 7.6 7.7 7.9 8.1 8.2 8.3 8.4 8.5 8.7Other 6.6 6.7 6.8 6.9 7 7.2 7.3 7.4 7.5 7.6 7.7
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
NorthAmerica 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2
Mercosur 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2WesternEurope 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2
CentralEurope 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2
Russia 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2Japan 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2China 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2India 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2Korea 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2Thailand 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2Other 3.02 3.03 3.05 3.06 3.08 3.1 3.12 3.13 3.15 3.16 3.2
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
Copyright 2013, just-auto Generated on 11 April 2013 84
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[236][236]March 26, 2013
[237][237]March 22, 2013
Other materials used in vehicle manufacture include rubber (mainly tyres although other uses inlcude wiper blades, engine
mounts, seals, hoses and belts), polypropylene (typically used in bumper construction although increasingly proposed as an
alternative to metal bodywork), elastomeric substances, organic materials, adhesives, nylon, textiles, fabrics (woven and
knitted), felt, cardboard, wires, etc.
The following table sets out ‘other materials’ as a percentage of total kerb weight of a medium-sized passenger car.
Other materials as a percentage of total kerb weight of medium-sizedOther materials as a percentage of total kerb weight of medium-sizedpassenger cars assembled in all major car producing regions, 2007-2027passenger cars assembled in all major car producing regions, 2007-2027
Source(s)Source(s) just-auto
Other-materials-as-a-percentage-of-total_136396526058035.csv
NewsNEW YORK SHOW: New platform & seven seats for Range...NEW YORK SHOW: New platform & seven seats for Range...
The second generation of Land Rover's Range Rover Sport is making its world premiere at the New York International Auto
Show. The main news is a 5+2 seating format, the choice of two 4x4 systems, plus a diesel hybrid and four-cylinder variants
to...
US: 3M launches Scotchshield automotive security f ilmsUS: 3M launches Scotchshield automotive security f ilms
According to the National Insurance Crime Bureau (NICB), an auto theft occurs every 33 seconds in the US. That's roughly
one million vehicles each year that wind up in the hands of thieves at a cost of nearly US$6.4bn.3M is making it easier for...
GERMANY: Renault-Nissan chooses ZF’s l ightweight plastic.. .GERMANY: Renault-Nissan chooses ZF’s l ightweight plastic.. .
Lightweight design is one of the key technologies when it comes to reducing the energy consumption of vehicles. However,
automotive manufacturers and suppliers are not able to draw on a superordinate patent solution. In actual fact, the sum of...
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
NorthAmerica 23.4 23.4 23.4 23.4 23.4 23.2 23.2 23.1 23.1 23 22.9
Mercosur 26.2 26.2 26.3 26.3 26.4 26.2 26.2 26.2 26.2 26.2 26.3WesternEurope 24.3 24.3 24.3 24.3 24.3 24.2 24.2 24.2 24.1 24.1 24
CentralEurope 25.2 25.2 25.2 25.3 25.2 25.3 25.3 25.3 25.2 25.2 25.1
Russia 26.8 26.9 26.9 27 27 27.1 27.1 27.1 27.1 27.1 27.1Japan 24.7 24.7 24.7 24.7 24.7 24.7 24.7 24.6 24.6 24.5 24.5China 26.4 26.4 26.5 26.5 26.5 26.5 26.5 26.5 26.4 26.4 26.4India 27 27.1 27.1 27.1 27.1 27.1 27.1 27.1 27.1 27.1 27Korea 25.9 26 26 26 26 26 26 26 26 25.9 25.9Thailand 25.7 25.7 25.7 25.8 25.8 25.9 25.9 25.9 25.9 25.9 25.9Other 27.4 27.4 27.5 27.5 27.5 27.7 27.7 27.7 27.8 27.8 27.8
Region 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
Copyright 2013, just-auto Generated on 11 April 2013 85
[238][238]March 22, 2013
[239][239]March 13, 2013
[240][240]March 12, 2013
[241][241]March 6, 2013
[242][242]February 12, 2013
[243][243]February 11, 2013
[244][244]February 8, 2013
SWEDEN: Volvo to del iver intercity buses to Faure in FranceSWEDEN: Volvo to del iver intercity buses to Faure in France
Volvo Bus France has signed an order with Faure, a large French public transport operator, on six vehicles Volvo 8900 RLE (13
metres). The buses are low-entry, and the body is built on the principle of best choice materials. The use of aluminium...
CANADA: Magna shapes the future of high-volume carbon f iber...CANADA: Magna shapes the future of high-volume carbon f iber...
Magna International Inc. has announced that its Magna Exteriors and Interiors (MEI) operating unit, together with strategic
development partner Zoltek, offers best-in-class capabilities in providing carbon fiber composite parts and systems for...
SOUTH KOREA: SsangYong reveals nano tube glass defrostingSOUTH KOREA: SsangYong reveals nano tube glass defrosting
SsangYong Motor has released initial details of a nano tube technology-based innovation for heating and defrosting vehicle
glass.
BELGIUM: Plastic Omnium axes plant in further European...BELGIUM: Plastic Omnium axes plant in further European...
Plastic Omnium is accelerating the pace of its European bumper production downsizing with today's (6 March) news it is to
shutter its fender manufacturing plant in Herentals, Belgium, this summer with the loss of 123 jobs.
The development...
US: Chevrolet Corvette gets l ighter with ‘smart material .. .US: Chevrolet Corvette gets l ighter with ‘smart material .. .
General Motors has revealed the weight-saving benefits from the use of so-called 'smart materials' in the latest Chevrolet
Corvette.
The new model is the first vehicle to use a General Motors'-developed lightweight shape memory alloy...
AUSTRALIA: Standard self-parking for new Holden VF CommodoreAUSTRALIA: Standard self-parking for new Holden VF Commodore
General Motors Holden has revealed its next Commodore sedan to the media at a special preview event in Melbourne. More
than a facelift but less than a redesign, the VF series model brings with it the most advanced technology yet seen on an...
NETHERLANDS: Tata Steels upgrades research facil ityNETHERLANDS: Tata Steels upgrades research facil ity
Tata Steels is starting a EUR2.3m facility at its Ijmuiden site in The Netherlands to develop crash-resistant steels.
The research and development investment follows collaboration between Tata Steels and three major European car
manufacturers...
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[246][246]March 8, 2013
[247][247]February 20, 2013
[248][248]February 4, 2013
[249][249]November 20, 2012
[250][250]November 12, 2012
[251][251]November 2, 2012
Interviews and insightsGENEVA 2013 PRESS PREVIEW DAYS REVIEW: Part Two (of two)GENEVA 2013 PRESS PREVIEW DAYS REVIEW: Part Two (of two)
Having peered under concepts to check for real engines and suspension systems, and gently interrogated multiple industry
executives in the quest to slake readers' insatiable thirsts for knowledge, Glenn Brooks now reports his findings.
Q&A with Zircotec: Thermal management solutions for the...Q&A with Zircotec: Thermal management solutions for the...
Based in Oxfordshire, UK Zircotec is a specialist coatings company that produces a range of proprietary plasma-sprayed
metal and ceramic coatings to protect materials from the damaging effects of heat, abrasion and wear. Over the past year,
Zircotec has been working with Aston Martin to provide thermal management solutions for its exclusive new supercar, the
One-77. Matthew Beecham talked with Terry Graham, managing director of Zircotec to find out how their products were
used in the supercar.
PRODUCT EYE: 2013 Citroen DS5 HYbrid4PRODUCT EYE: 2013 Citroen DS5 HYbrid4
Wh o says th e British won't pay premium prices for F rench cars? Citroen h as b een quietly moving itselfWh o says th e British won't pay premium prices for F rench cars? Citroen h as b een quietly moving itself
upmarket in th e UK , enjoying much success with its DS line veh icles. Glenn Brooks tries th e latest model,upmarket in th e UK , enjoying much success with its DS line veh icles. Glenn Brooks tries th e latest model,
th e diesel-electric DS5 HYb rid4 in new 88g/km form.th e diesel-electric DS5 HYb rid4 in new 88g/km form.
RESEARCH ANALYSIS: Use of carbon f ibre in vehicle...RESEARCH ANALYSIS: Use of carbon f ibre in vehicle...
Carbon fibre reinforced plastics have been drawing industry attention as their lightness and strength can help the fuel
efficiency of vehicles, but the time-consuming work required to produce the materials is a drawback. Here, Matthew
Beecham talked with experts from Prodrive Composites, Zircotec and the University of Nottingham about the use of carbon
fibre in vehicle manufacture.
Q&A with Nottingham University: Recycl ing carbon f ibre...Q&A with Nottingham University: Recycl ing carbon f ibre...
A team of researchers at Nottingham University, led by Professor Steve Pickering, Hives Professor of Mechanical
Engineering, are developing processes to recycle carbon fibre composite materials, including developing applications for use
of the recycled carbon fibre. Matthew Beecham talked to the Professor to find out how these processes can be applied to
the automotive industry.
Q&A with Prodrive: Carbon f ibre in vehicle manufactureQ&A with Prodrive: Carbon f ibre in vehicle manufacture
Carbon fibre reinforced plastics have been drawing industry attention as their lightness and strength can help the fuel
Copyright 2013, just-auto Generated on 11 April 2013 87
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[253]
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[254][254]May 1, 2012
[255][255]February 29, 2012
[256][256]December 6, 2011
[223][223]March 22, 2013
[226][226]March 22, 2013
efficiency of vehicles, but the time-consuming work required to produce the materials is a drawback. Here, Matthew
Beecham talked with Gary White, engineering manager, Prodrive Composites about the use of carbon fibre in vehicle
manufacture.
ANALYSIS: Details of Renault X98 Clio build process &...ANALYSIS: Details of Renault X98 Clio build process &...
Renault has announced yet more details of the fourth generation Clio , ahead of the car's global debut at the Paris motor
show. These include how and where the model will be built, as well as the means used to attain a claimed 100kg average
weight saving.
INTERVIEW: JAPIA MD Takehide Takahashi on Nylon 12 shortageINTERVIEW: JAPIA MD Takehide Takahashi on Nylon 12 shortage
Headquartered in Tokyo, Japan's supplier organisation, JAPIA (Japan Auto Parts Industry Association) is rapidly assessing the
impact of the recent catastrophic explosion at Nylon 12 resin producer, Evonik's factory in Germany.
JAPIA executive managing director Takehide Takahashi spoke to Simon Warburton from Tokyo about how the association
was addressing the situation and what impact it could have on Japan's supply chain, despite what appears to be difficulty in
obtaining information about the lack of PA12.
February 2012 management brief ing: key trends in global.. .February 2012 management brief ing: key trends in global.. .
Joined at th e seamJoined at th e seam
In the f inal part of this three-part series looking at the trends in global manufacturing, Jul ian BuckleyIn the f inal part of this three-part series looking at the trends in global manufacturing, Jul ian Buckley
examines the different joining methods available to carbody special ists to determine if traditional spotexamines the different joining methods available to carbody special ists to determine if traditional spot
welding has had its daywelding has had its day
INTERVIEW: Tata Steel Europe chief commercial off icer,.. .INTERVIEW: Tata Steel Europe chief commercial off icer,.. .
Tata Steel - one of the world's largest producers - recently held a Supplier Connection Day at the Heritage Motor Centre
museum and conference centre in Gaydon, UK. The mini-conference featured presentations from Tata Steel experts
covering each of the major automotive disciplines. Tata Steel Europe chief commercial officer Henrik Adam talked to just-
auto about how the company is evolving as the day outlined how the effective deployment of steel technologies can lower
the total cost of ownership of steel throughout the supply chain.
Tables and figuresAluminium as a percentage of total kerb weight of medium-sized passenger carsAluminium as a percentage of total kerb weight of medium-sized passenger cars
assembled in all major car producing regions, 2007-2027assembled in all major car producing regions, 2007-2027
Plastics as a percentage of total kerb weight of medium-sized passenger cars assembled inPlastics as a percentage of total kerb weight of medium-sized passenger cars assembled inall major car producing regions, 2007-2027all major car producing regions, 2007-2027
Copyright 2013, just-auto Generated on 11 April 2013 88
[216][216]March 22, 2013
[232][232]March 22, 2013
[207][207]February 19, 2013[213][213]February 19, 2013[210][210]February 19, 2013[202][202]February 19, 2013[257][257]February 19, 2013
[219][219]December 17, 2012
Steel as a percentage of total kerb weight of medium-sized passenger cars assembled inSteel as a percentage of total kerb weight of medium-sized passenger cars assembled inall major car producing regions, 2007-2027all major car producing regions, 2007-2027
Other materials as a percentage of total kerb weight of medium-sized passenger carsOther materials as a percentage of total kerb weight of medium-sized passenger carsassembled in all major car producing regions, 2007-2027assembled in all major car producing regions, 2007-2027
Examples of alternative materials to steelExamples of alternative materials to steel
Cost of CO2 savingCost of CO2 saving
Evaluation of a clutch pedalEvaluation of a clutch pedal
Alternative materials: potential weight saving versus costAlternative materials: potential weight saving versus cost
Passenger car weight: Examples of some popular models over the past 30 yearsPassenger car weight: Examples of some popular models over the past 30 years
Iron as a percentage of total kerb weight of medium-sized passenger cars assembled inIron as a percentage of total kerb weight of medium-sized passenger cars assembled inall major car producing regions, 2007-2027all major car producing regions, 2007-2027
Source UR L:Source UR L: http://qube.just-auto.com/material-trends-intelligence-service
Links:Links:
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[30] http://qube.just-auto.com/alcoa-inc
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[36] http://www.alcoa.com/global/en/home.asp
[37] https://twitter.com/Alcoa
[38] http://www.youtube.com/user/alcoatv
[39] http://www.linkedin.com/company/alcoa
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[40] http://www.facebook.com/alcoa
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[48] http://www.linkedin.com/company/basf
[49] https://twitter.com/BASF
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[51] http://www.youtube.com/user/BASF
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[59] http://www.materialscience.bayer.com/
[60] http://www.facebook.com/BayerMaterialScienceAEV
[61] http://www.linkedin.com/company/bayer-materialscience
[62] https://twitter.com/bayerbmsllc
[63] http://www.youtube.com/playlist?list=PL9C1497E39C803B3F
[64] http://qube.just-auto.com/benteler-ag
[65] http://qube.just-auto.com/benteler-ag#sectors
[66] http://qube.just-auto.com/benteler-ag#interviews
[67] http://qube.just-auto.com/benteler-ag#presentations
[68] http://qube.just-auto.com/benteler-ag#news
[69] http://qube.just-auto.com/benteler-ag#competitors
[70] http://www.benteler.com/
[71] http://qube.just-auto.com/cie-automotive-sa
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[73] http://qube.just-auto.com/cie-automotive-sa#interviews
[74] http://qube.just-auto.com/cie-automotive-sa#presentations
[75] http://qube.just-auto.com/cie-automotive-sa#news
[76] http://qube.just-auto.com/cie-automotive-sa#competitors
[77] http://www.cieautomotive.com/
[78] http://www.linkedin.com/company/cie-automotive
[79] http://qube.just-auto.com/cooper-standard-automotive-inc
[80] http://qube.just-auto.com/cooper-standard-automotive-inc#sectors
[81] http://qube.just-auto.com/cooper-standard-automotive-inc#interviews
[82] http://qube.just-auto.com/cooper-standard-automotive-inc#presentations
[83] http://qube.just-auto.com/cooper-standard-automotive-inc#news
[84] http://qube.just-auto.com/cooper-standard-automotive-inc#competitors
[85] http://www.cooperstandard.com/index.php
[86] http://www.facebook.com/pages/Cooper-Standard-Automotive/113588648659135
[87] http://www.linkedin.com/company/cooper-standard-automotive
[88] https://twitter.com/cooperstandard
[89] http://qube.just-auto.com/dow-automotive-systems
[90] http://qube.just-auto.com/dow-automotive-systems#sectors
[91] http://qube.just-auto.com/dow-automotive-systems#interviews
[92] http://qube.just-auto.com/dow-automotive-systems#presentations
[93] http://qube.just-auto.com/dow-automotive-systems#news
[94] http://qube.just-auto.com/dow-automotive-systems#competitors
[95] http://www.dowautomotive.com/
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[99] http://qube.just-auto.com/dupont-e-i-du-pont-de-nemours-and-company#sectors
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[103] http://qube.just-auto.com/dupont-e-i-du-pont-de-nemours-and-company#competitors
[104] http://www2.dupont.com/automotive/en-us/au/index.html
[105] https://twitter.com/DuPont_News
[106] http://www.linkedin.com/company/dupont
[107] http://www.youtube.com/user/DuPont
[108] http://qube.just-auto.com/faurecia-sa
[109] http://qube.just-auto.com/faurecia-sa#sectors
[110] http://qube.just-auto.com/faurecia-sa#interviews
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[114] http://www.faurecia.com/Pages/Default.aspx
[115] http://www.linkedin.com/company/faurecia
[116] https://twitter.com/faurecia_na
[117] http://www.facebook.com/FaureciaNA
[118] http://qube.just-auto.com/freudenberg-co-kg
[119] http://qube.just-auto.com/freudenberg-co-kg#sectors
[120] http://qube.just-auto.com/freudenberg-co-kg#interviews
[121] http://qube.just-auto.com/freudenberg-co-kg#presentations
[122] http://qube.just-auto.com/freudenberg-co-kg#news
[123] http://qube.just-auto.com/freudenberg-co-kg#competitors
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[126] https://twitter.com/freudenberg_ger
[127] http://www.facebook.com/freudenberggroup
[128] http://qube.just-auto.com/magna-international-inc
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[130] http://qube.just-auto.com/magna-international-inc#interviews
[131] http://qube.just-auto.com/magna-international-inc#presentations
[132] http://qube.just-auto.com/magna-international-inc#news
[133] http://qube.just-auto.com/magna-international-inc#competitors
[134] http://www.magna.com/
[135] http://www.linkedin.com/company/magna-international
[136] https://twitter.com/magnaint
[137] http://www.facebook.com/MagnaInternational
[138] http://www.youtube.com/topic/kxEu3A9qnp8/magna-international
[139] http://qube.just-auto.com/martinrea-international-inc
[140] http://qube.just-auto.com/martinrea-international-inc#sectors
[141] http://qube.just-auto.com/martinrea-international-inc#interviews
[142] http://qube.just-auto.com/martinrea-international-inc#presentations
[143] http://qube.just-auto.com/martinrea-international-inc#news
[144] http://qube.just-auto.com/martinrea-international-inc#competitors
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[146] http://www.linkedin.com/company/martinrea-international
[147] http://qube.just-auto.com/ppg-industries
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[149] http://qube.just-auto.com/ppg-industries#interviews
[150] http://qube.just-auto.com/ppg-industries#presentations
[151] http://qube.just-auto.com/ppg-industries#news
[152] http://qube.just-auto.com/ppg-industries#competitors
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[153] http://www.ppg.com/en/Pages/home.aspx
[154] http://www.facebook.com/ppgindustries
[155] https://twitter.com/ppgindustries
[156] http://www.youtube.com/user/ppgindustriesinc
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[159] http://qube.just-auto.com/samvardhana-motherson-group#interviews
[160] http://qube.just-auto.com/samvardhana-motherson-group#presentations
[161] http://qube.just-auto.com/samvardhana-motherson-group#news
[162] http://qube.just-auto.com/samvardhana-motherson-group#competitors
[163] http://www.motherson.com/
[164] http://qube.just-auto.com/sumitomo-corporation
[165] http://qube.just-auto.com/sumitomo-corporation#sectors
[166] http://qube.just-auto.com/sumitomo-corporation#interviews
[167] http://qube.just-auto.com/sumitomo-corporation#presentations
[168] http://qube.just-auto.com/sumitomo-corporation#news
[169] http://qube.just-auto.com/sumitomo-corporation#competitors
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[176] http://qube.just-auto.com/thyssenkrupp-ag#news
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[178] http://www.thyssenkrupp.com/
[179] http://www.linkedin.com/company/thyssenkrupp
[180] http://www.thyssenkrupp.com/en/twitter/index.html
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[183] http://qube.just-auto.com/trelleborg-ab#sectors
[184] http://qube.just-auto.com/trelleborg-ab#interviews
[185] http://qube.just-auto.com/trelleborg-ab#presentations
[186] http://qube.just-auto.com/trelleborg-ab#news
[187] http://qube.just-auto.com/trelleborg-ab#competitors
[188] http://www.trelleborg.com/en/
[189] http://www.linkedin.com/company/trelleborg
[190] http://twitter.com/trelleborggroup
[191] http://www.facebook.com/Trelleborggroup
[192] http://www.youtube.com/trelleborg
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[194] http://qube.just-auto.com/woodbridge-group#sectors
[195] http://qube.just-auto.com/woodbridge-group#interviews
[196] http://qube.just-auto.com/woodbridge-group#presentations
[197] http://qube.just-auto.com/woodbridge-group#news
[198] http://qube.just-auto.com/woodbridge-group#competitors
[199] http://www.woodbridgegroup.com/
[200] http://www.linkedin.com/company/the-woodbridge-group
[201] http://www.facebook.com/pages/The-Woodbridge-Group/152931508117494
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[211] http://qube.just-auto.com/sites/qube.just-auto.com/files/datatables/Evaluation-of-a-clutch-pedal_13612760122392.csv
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[257] http://qube.just-auto.com/reportdatatable/passenger-car-weight-examples-some-popular-models-over-past-30-years
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