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FY 2005 Progress Report for High Strength Weight Reduction Materials

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FY 2005 Progress Report for High Strength Weight Reduction Materials Annual Progress Report HIGH STRENGTH WEIGHt REDUCTION MATERIALS Less dependence on foreign oil, and eventual transition to an emissions-free, petroleum-free vehicle A Strong Energy Portfolio for a Strong America F R E E D O M C A R A N D V E H I C L E T E C H N O L O G I E S P R O G R A M Energy efficiency and clean, enewabler energy will mean a stronger economy, a cleaner environment, and greater energy independence for America. Working with a wide array of state, community, industry, and university partners, the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy invests in a diverse portfolio of energy technologies. For more information contact: EERE Information Center 1-877-EERE-INF (1-877-337-3463) www.eere.energy.gov Acknowledgement We would like to express our sincere appreciation to QSS Group, Inc., Oak Ridge National Laboratory, and Argonne National Laboratory for their technical and artistic contributions in preparing and publishing this report. In addition, we would like to thank all the participants for their contributions to the pro­ grams and all the authors who prepared the project abstracts that comprise this report. This document highlights work sponsored by agencies of the U.S. Government. Neither the U.S. Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the U.S. Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the U.S. Government or any agency thereof. Printed on recycled paper U.S. Department of Energy Office of FreedomCAR and Vehicle Technologies 1000 Independence Avenue S.W. Washington, DC 20585-0121 FY 2005 Progress Report for High Strength Weight Reduction Materials Energy Efficiency and Renewable Energy Office of FreedomCAR and Vehicle Technologies Advanced Materials Technologies Edward Wall Program Manager, OFCVT Rogelio Sullivan Advanced Materials Technologies Team Leader James Eberhardt Chief Scientist August 2006 High Strength Weight Reduction Materials FY 2005 Annral Report CONTENTS 1. INTRODUCTION............................................................................................................................. 1 2. MATERIALS DEVELOPMENT .................................................................................................... 3 A. Advanced Materials for Friction Brakes..................................................................................... 3 B. Integrated Approach for Development of Energy-Efficient Steel Components for Heavy Vehicle and Transportation Applications........................................................................ 8 C. Development of Technologies for the Application of Magnesium Metal Matrix Composites for Heavy Vehicles ................................................................................................. 16 D. Lightweight Functional Composite Materials ............................................................................ 25 3. MATERIALS PROCESSING TECHNOLOGIES....................................................................... 31 A. Laser Glazing and Friction Stir Processing of Materials to Reduce Friction ............................. 31 B. Development of an Advanced Squeeze Casting Process for the Production of High-Integrity Truck Components ............................................................................................. 38 C. Wrought Magnesium Alloy/Process Development .................................................................... 43 D. Thermomechanical Processing of Ti and Ti-6Al-4V Sheet and Plate from Low Cost Powders...................................................................................................................... 50 E. Counter Gravity (Hitchiner) and Pressure Assisted Lost Foam Magnesium Casting ................ 57 4. ENABLING TECHNOLOGIES...................................................................................................... 65 A. Joining of Advanced Materials by Plastic Deformation............................................................. 65 B. Rapid, Low-Cost Tooling Development..................................................................................... 72 C. Improved Friction Tests for Engine Materials............................................................................ 75 D. Equal Channel Angular Extrusion Processing of Alloys for Improved Mechanical Properties ................................................................................................................ 79 E. Attachment Techniques for Heavy Truck Composite Chassis Members ................................... 86 F. Laser Texturing of Propulsion Materials.................................................................................... 95 G. Friction Stir Joined Aluminum Sheet Materials for Heavy Vehicle Cab Structures .................. 103 H. Friction Stir Joining and Processing of Advanced Materials Including MMCs......................... 112 I. Friction Stir Welding and Processing of Advanced Materials ................................................... 122 J. Portfolio Analysis for Lightweight Materials............................................................................. 135 K. Inventory of Heavy-Duty Truck Lightweighting Candidates..................................................... 137 L. Basic Studies of Ultrasonic Welding for Advanced Transportation Systems ............................ 143 M. Effects of Highway Ice-Clearing Treatments on Corrosion of Heavy Vehicle Materials and Components ......................................................................................................... 153 5. LIGHTWEIGHT VEHICLE STRUCTURES ............................................................................... 161 A. Lightweight Trailer-Liburndas Project....................................................................................... 161 B. Application of Superplastically Formed Aluminum for Truck Body Panels ............................. 166 C. Advanced Composite Support Structures................................................................................... 169 D. New-Generation Frame for Pickup/Sport Utility Vehicle Application ...................................... 177 E. Advanced Superplastic Forming Development for Heavy Vehicle Structures .......................... 179 F. Development of Magnesium for Heavy Vehicle Powertrain Components ................................ 184 iii FY 2005 Annual Report High Strength Weight Reduction Materials CONTENTS (CONT.) G. Lightweight Stainless Steel Bus Frame—Phase III.................................................................... 188 H. Side Impact Analysis of a Lightweight Stainless Steel Bus Structure........................................ 193 I. Stainless Steel Bus Structure – Manufacturing Cost Analysis ................................................... 198 6. APPLICATION OF INNOVATIVE MATERIALS ...................................................................... 203 A. Carbon Fiber SMC for Class 8 Vehicle Hoods .......................................................................... 203 B. Application of Carbon Fiber for Large Structural Components................................................. 207 C. Hybrid Composite Materials for Weight-Critical Structures...................................................... 213 D. Advanced Composite Structural Cab Components .................................................................... 216 E. Advanced Composite Structural Chassis Components............................................................... 223 iv High Strength Weight Reduction Materials FY 2005 Progress Report 1. INTRODUCTION The energy consumption of on-road heavy trucks has been increasing due to the growth in demand for freight delivery as the U.S. economy continues to expand. The recent rapid rise in fuel prices has raised fuel costs to be the number one concern of the trucking industry. Owners and operators of trucks and truck fleets have been operating on “razor thin” margins and increasing the fuel economy of their vehicles is one way of reducing their fuel costs to remain viable as a business. One way of achieving heavy vehicle fuel economy improvements without sacrificing revenue earnings limited by maximum allowable vehicle weight or volume is through the use of high strength weight reduction materials for either or both the tractor and trailer. Vehicle weight reduction results in reduced parasitic energy losses and improved overall vehicle fuel efficiency by enabling more ton-miles per gallon of fuel consumed. In addition, it is recognized that improved materials may enable the implementation of other technologies that can further improve the fuel efficiency of heavy vehicles. The High-Strength Weight Reduction (HSWR) Materials Technology activity of the U.S. Department of Energy’s (DOE’s) Office of FreedomCAR and Vehicle Technologies (OFCVT) Program seeks to reduce the weight of heavy vehicles without reducing vehicle functionality, durability, reliability, or safety
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