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Tesla's Cybertruck Is Audaciously Austenitic AE Marubeni Ad 0620.qxp 6/3/20 1:26 PM Page 1 Citizen Productivity, Miyano Precision Supported by MCC’s local, full service distributor network. Experience the difference. BNA-42MSY2 CNC Super Turning Center with 2 Spindles and 1 Turret with Y-Axis Enhanced front and back simultaneous machining capability. Not your basic single turret, twin spindle machine The X2 axis sub-spindle and superimposed synchronization enables simultaneous, independent machining of the front and back of the workpiece. This, in effect, provides the benefi ts of a twin turret machine with the signifi cant cost savings of a single turret model. • Increased power on spindle motors Machine specifi cations • High torque revolving tool motor provides heavier cutting Max. machining diameter 1 5/8" • Fast processing and short cycle time with the high speed NC unit Standard machining length 3.9" • Cincom Control ensures reduced idle time and easy setup Main spindle speed 60 ~ 6,000 • Compact design for fl oor space effi ciency Rotary tool spindle speed 60 ~ 6,000 Back spindle speed 50 ~ 5,000 www.marucit.com Allendale, NJ Elk Grove Village, IL Fountain Valley, CA Agawam, MA (201) 818-0100 (847) 364-9060 (714) 434-6224 (413) 786-6655 Free Info at http://info.hotims.com/76516-712 AUTOMOTIVE ENGINEERING® LIGHTWEIGHT METALS SPECIAL Megacasting muscle! Tesla Model Y goes big on aluminum castings with help from Italy’s Last Chance to Enter! IDRA Group Change the world, achieve global recognition, and win $20,000. Entry Deadline: July 1, 2020 CreateTheFutureContest.com Sergey Nivens/Shutterstock.com CTF Belly Band Lightbulb.indd 1 5/13/20 4:04 PM ALSO IN THIS ISSUE: Stainless steel for Cybertruck Tata Steel innovations Mixed-materials design tools June 2020 autoengineering.sae.org Last Chance to Enter! Change the world, achieve global recognition, and win $20,000. Entry Deadline: July 1, 2020 CreateTheFutureContest.com Sergey Nivens/Shutterstock.com CTF Belly Band Lightbulb.indd 1 5/13/20 4:04 PM AUTOMOTIVE ENGINEERING® LIGHTWEIGHT METALS SPECIAL Megacasting muscle! Tesla Model Y goes big on aluminum castings with help from Italy’s IDRA Group ALSO IN THIS ISSUE: Stainless steel for Cybertruck Tata Steel innovations Mixed-materials design tools June 2020 autoengineering.sae.org CONTENTS FEATURES REGULARS 12 Lightweight Metals Special 2 Editorial: Impressions of a rocket launch 12 Tesla casts a new strategy for light- 4 SAE Standards News weight structures COVER STORY The EV maker boldly invests in the world’s largest aluminum die- 5 Supplier Eye casting machine to manufacture entire rear underbody structures. 6 What We’re Driving 16 Steel the Real Deal MATERIALS 7 Technology Report Steel’s infinite recyclability will help it remain the auto industry’s 7 Can CHAdeMO 3.0 standardize global EV material of choice, insists Tata Steel Europe’s CCO. quick-charging? | ELECTRIFICATION 8 Cummins and Tula test ‘dynamic’ cylinder 19 Tesla’s Cybertruck is audaciously deactivation for diesels | PROPULSION STAINLESS STEEL | MATERIALS austenitic 10 Customization drives new Porsche paint A proprietary 301-series stainless steel gives Tesla’s first pickup process | MANUFACTURING truck unique sales attributes while saving tooling cost. 22 Product Briefs 20 Lightweight design beyond CAD Spotlight: Adhesives & Electronics COMPUTATIONAL DESIGN 26 Companies Mentioned, Ad Index New computational tools enable an integrated data-fusion approach to complex, mixed-materials engineering. An expert 28 Q&A from nTopology explains. Paul Platte discusses Covestro’s new polycarbonate solutions ON THE COVER Tesla is moving to a single, large aluminum casting for the rear structural underbody of its Model Y high-volume sedan as well as Follow us on social media future versions of Model 3. Enabling this new ‘megacasting’ is the world’s largest high-pressure die casting machine supplied by Italy-based IDRA Group, whose OL5500CS is shown. Tesla will eventually have two of these machines at its Fremont plant, plus one in Berlin and one in Shanghai. (Tesla and IDRA Group images) @SAEAutoMag @saeaei SAE Magazines Automotive Engineering®, June 2020, Volume 7, Number 5. Automotive Engineering (ISSN 2331-7639) is published in January/February, March, April, May, June, July/August, 16 September, October, November/December by Tech Briefs Media Group, an SAE International Company ®, 261 Fifth Avenue, Suite 1901, New York, NY 10016 and printed in Mechanicsburg, PA. Copyright © 2020 SAE International. Annual print subscription for SAE members: first subscription, $15 included in dues; additional single copies, $30 each North America, $35 each overseas. Prices for nonmember subscriptions are $115 North America, $175 overseas. Periodicals postage paid at New York, and additional mailing offices. POSTMASTER: Please send address changes to Automotive Engineering, P. O. Box 3525, Northbrook, IL 60062. SAE International is not responsible for the accuracy of information in the editorial, articles, and advertising sections of this publication. Readers should independently evaluate the accuracy of any statement in the editorial, articles, and advertising sections of this publication that are important to him/her and rely on his/her independent evaluation. For permission to reproduce or use content in other media, contact [email protected]. To purchase reprints, contact [email protected]. Claims for missing issues of the magazine must be submitted within a six-month time frame of the claimed issue’s publication date. The Automotive Engineering title is registered in the U.S. Patent and Trademark Office. Full issues and feature articles are included in the SAE Digital Library. For additional information, free demos are available at www.saedigitallibrary.org. (ISSN 2331-7639 print) (ISSN 2331-7647 digital) Audited by II June 2020 AUTOMOTIVE ENGINEERING AE Elektro Automatik Ad 0320_Version 2.qxp_Layout 1 2/14/20 4:56 PM Page 1 Free Info at http://info.hotims.com/76516-701 NY, NJ, OH: EDITORIAL Ryan Beckman +1.973.409.4687 Bill Visnic [email protected] Editorial Director [email protected] PA/DE: Desiree Stygar Lindsay Brooke +1.908.300.2539 Editor-in-Chief [email protected] [email protected] Midwest/Great Lakes: EDITORIAL Paul Seredynski IN, MI, WI, IA, IL, MN Senior Editor [email protected] Chris Kennedy +1.847.498.4520, x3008 Ryan Gehm [email protected] Associate Editor [email protected] Midwest/Central Canada: KS, KY, MO, NE, ND, SD, ON, MB Impressions of a rocket launch Jennifer Shuttleworth Bob Casey Associate Editor +1.847.223.5225 For a brief but illuminating moment, and SpaceX pioneered it. [email protected] [email protected] advanced engineering at its finest was The Demo-2 journey validated the Lisa Arrigo Southern CA, AZ, NM, Custom Electronic Rocky Mountain States: on the world stage. The May 30, 2020, Crew Dragon/Falcon 9 combination, Products Editor Tim Powers [email protected] +1.424.247.9207 launch from Cape Canaveral of two with more to come. SpaceX holds a [email protected] American astronauts, destined for the $2.6-billion contract with NASA’s Contributors Northern CA, WA, OR, Western Canada: orbiting International Space Station Commercial Crew Program to fly six Kami Buchholz Twyla Sulesky (ISS), marked the first time since 2011 operational crewed missions to the ISS. Detroit Editor +1.408.779.0005 Stuart Birch [email protected] that the U.S. put humans into space Significantly, the capsule, booster European Editor from home soil. systems and the Merlin engine family Terry Costlow International Electronic Technologies Editor The reawakening of the U.S. space were all designed and developed by the Europe – Central & Eastern: Bradley Berman Sven Anacker program is invigorating to those who California-based aerospace company. U.S. West Coast Editor Britta Steinberg understand the value of technical Its record of 85 launches, 46 landings +49.202.27169.11 Sebastian Blanco, Don Sherman, [email protected] achievement on a grand scale—and and 31 reflown rockets, and its success- Paul Weissler [email protected] who simply love seeing giant rockets ful commercial-payload business, have Europe – Western: Chris Shaw blast off into the sky. And proved SpaceX’s credibility DESIGN +44.1270.522130 [email protected] its joint public-private to even the most skeptical Lois Erlacher It’s no surprise Creative Director China: partnership of NASA and among NASA’s slide-rule- Alan Ao Ray Carlson +86.21.6140.8920 SpaceX is historic. The that Musk’s era retirees. The company Associate Art Director [email protected] iconic government agency also earns praise for its Japan: companies Shigenori Nagatomo provided funding, its hall- cost efficiency. As an avia- SALES & +81.3.3661.6138 mark safety oversight and are magnets tion analyst remarked, “You MARKETING [email protected] crew for the recent Demo- won’t find $500 screwdriv- Joe Pramberger South Korea: for young Publisher Eun-Tae Kim 2 spaceflight. SpaceX, ers at Hawthorne.” [email protected] +82-2-564-3971/2 engineering [email protected] founded in 2002 by a pre- The Demo-2 mission gen- Kaitlyn Sommer erated enormous positive Marketing Director Tesla Elon Musk, supplied talent. [email protected] Integrated Media the mission’s Crew Dragon publicity for Elon Musk, in- Martha Tress Consultants capsule and reusable Falcon-9 rocket. cluding the canny use of two Model X Recruitment Sales Manager +1.724.772.7155 Angelo Danza [email protected] +1.973.874.0271 The Falcon unleashes nearly 23,000 Teslas (wearing large NASA logos) to [email protected] kN (5,130,000 lbf) of thrust at sea-level transport the astronauts to the launch Christian DeLalla liftoff, courtesy of its 27 Merlin 1D en- pad. For the tech-savvy viewer/EV cus- REGIONAL +1.973.841.6035 [email protected] gines. A 1,500-horsepower Bugatti tomer, the May 30 space mission af- SALES Casey Hanson Chiron is a wimp by comparison.
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