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Chrysler Group Trends for Automotive Cast Materials

Chrysler Group Trends for Automotive Cast Materials Paul Bujalski Supervisor-Cast Metals Engineering DaimlerChrysler Corporation Materials Selection Trends for Automotive Cast Materials Drivers Lower total vehicle cost Manpower Investment Materials Meet new performance requirements

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Chrysler Group Trends for Automotive Cast Materials

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  1. Chrysler Group Trends for Automotive Cast Materials Paul Bujalski Supervisor-Cast Metals EngineeringDaimlerChrysler Corporation

  2. Materials Selection Trends for Automotive Cast Materials Drivers Lower total vehicle cost Manpower Investment Materials Meet new performance requirements Customer driven Government driven

  3. Materials Data Trends for Automotive Cast Materials Density (g/cm3)

  4. Materials Data Trends for Automotive Cast Materials Cost

  5. Materials Data Trends for Automotive Cast Materials Material Properties

  6. Ranking for Structural Applications Materials Data Trends for Automotive Cast Materials FRF = (Tensile x Modulus) (Cost x Density)

  7. Ferrous Applications Current Front Knuckle Control Arms Crankshafts Camshafts Engine Block Con Rods Thin-Wall Steel: BIW Structures (B- Pillar, etc.) Chassis Assemblies Austempered Ductile Iron: Crankshafts Suspension Components Future ? Typical Ferrous Suspension Castings

  8. Ferrous Applications Current Front Knuckle Control Arms Crankshafts Camshafts Engine Block Con Rods Thin-Wall Steel: BIW Structures (B- Pillar, etc.) Chassis Assemblies Austempered Ductile Iron: Crankshafts Suspension Components Future ? Thin-Wall Cast Steel Crossmember

  9. Aluminum Applications Current Front Knuckle Rear Knuckle Engine Cradle Road Wheel Engine Block Cylinder Head Transmission Case Space Frames (Cast Node/Extrusion Combination) BIW Closure Panels BIW Structures (B- Pillar, etc.) Future ? Pacifica / 300C / Magnum Rear Suspension Links Squeeze Casting Process Saves Cost over Forging

  10. Magnesium Applications Current Steering Wheel Instrument Panel Steering Column Brkt. Upper Mt. Brkt. Pedal Sup. Brkt. Future ? Viper Front of Dash Support Transfer Case Transmission Case Liftgate, Cradles Rear Seat Frame Front Radiator Support Oil Pan / Front Cover Super Integrated Design Saves Weight and Cost

  11. Steel will remain the dominant material. Iron will decrease but remain important. Composites will increase for low volume applications. Aluminum will grow and should become the number 2 material. Magnesium will have high growth rate, but remain below 1-3% of the vehicle. For the Future Summary Trends for Automotive Cast Materials

  12. Exterior Composites on the 2003 Dodge Viper = SMC = RRIM

  13. Structural Composites on the 2003 Dodge Viper = Glass Fiber SMC, LMC, GMT = Carbon Fiber SMC

  14. Thin-Wall Steel Castings-Integrating Weldments or Fabricated Assemblies into Single Component, BIW Structures. Austempered Ductile Iron, More Machinable ADI Grades Targeting Chassis Applications. Higher Strength Aluminum Alloys, 2xx/7xx Series. Wrought/Forging-Casting Process Combinations. Magnesium Castings in Powertrain and Chassis Applications. Specific Target Areas Summary Trends for Automotive Cast Materials

  15. Trends for Automotive Cast Materials Thank You For Your Attention. Any Questions?

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