Multi-material design for the optimization of the automotive production process

Abstract

The automotive industry and thus the automobile production processes have to face new challenges constantly. Changing mobility concepts, alternative approaches to mobility, urbanization and demographic change lead to alterations of the buying behavior of potential customers. This results in a higher rate of product diversity, which increases steadily. Through the constant growth of Asia and China, in particular as automotive manufacturing sites, and the gain in purchasing power of the population of emerging and developing countries, new markets appear, developing with high growth rates. This process has also impacts on the production technology. A key issue is the transition from finite fossil fuels to alternative fuels and drive systems. Significant rating values are CO2 and pollutant emissions. Downsizing conventional combustion engines and the use of alternative fuels are means to achieve minimization of emissions. Innovative electric motors, solar and fuel cells or hybrid solutions are other approaches to realize a pure electric vehicle. Requirements for that are suitable energy sources and storage systems. Another approach to reduce emissions is the application of new types of materials in the engine, chassis or body. These measures lead to weight reduction and therefore lower fuel consumption. Such materials require the development of entirely new process chains, which includes recycling, manufacturing processes and logistics concepts. Due to the availability of modern methods and materials, coming automobile generations will be realized by multi-material mixing. In this concept, the materials are combined and can be optimized according to the operational demands. The manufacturing, working and processing as well as the calculation of such structures and the development of associated process chains are enormous challenges for future car generations.