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Aluminum and Carbon Composites AE COMSOL Ad 0519.qxp_Layout 1 4/16/19 2:54 PM Page 1 Contact modeling functionality for fast and accurate results.results. Visualization of von Mises stress distribution and applied loads in a mixed-mode delamination of a composite material. Adhesion and decohesion modeling is useful for analyzing manufacturing processes that involve the joining of parts and for studying the maximum load-bearing capacity of structures. The right contact modeling tools deliver fast and accurate results, empowering you to develop more efficient and reliable manufacturing processes. The COMSOL Multiphysics® software is used for simulating designs, devices, and processes in all fields of engineering, manufacturing, and scientific research. See how you can apply it to contact modeling. comsol.blog/adhesion-decohesion Free Info at http://info.hotims.com/73005-718 AE COMSOL Ad 0519.qxp_Layout 1 4/16/19 2:54 PM Page 1 Contact modeling functionality for fast and accurate results.results. Visualization of von Mises stress distribution and applied loads in a mixed-mode delamination of a composite material. Adhesion and decohesion modeling is useful for analyzing manufacturing processes that involve the joining of parts and for studying the maximum load-bearing capacity of structures. The right contact modeling tools deliver fast and accurate results, empowering you to develop more efficient and reliable manufacturing processes. The COMSOL Multiphysics® software is used for simulating designs, devices, and processes in all fields of engineering, manufacturing, and scientific research. See how you can apply it to contact modeling. comsol.blog/adhesion-decohesion Free Info at http://info.hotims.com/73005-718 AUTOMOTIVE ENGINEERING® LIGHTWEIGHTING 2019 Steel stands strong Innovation drives the materials mix for new vehicle programs Inside JLR’s new inline-6 engine Design for additive manufacturing F1: Downforce battles turbulence May 2019 autoengineering.sae.org AE Gerdau Ad 0519.qxp_Layout 1 4/16/19 2:56 PM Page 1 Transforming our business to provide the best value for our customers. ³6DWLV¿HGFXVWRPHUV are good business!” Brock Miller – Caster Operator Gerdau is steel. For nearly half a century Gerdau has been a singular source of excellence for all your SBQ needs. And we’re getting better every day. More capacity, new capabilities, a renewed focus on service and delivery - all centered on adding value for our customers. All of our people are aware that our success depends on your www.gerdau.com/specialsteel success, and we thrive on accepting tough challenges head-on. Free Info at http://info.hotims.com/73005-701 CONTENTS FEATURES REGULARS 18 Lightweighting 2019 COVER STORY 2 Editorial: Choking on the haze of California vs. the Feds 18 Steel stands tall Through constant innovation, mobility’s longtime incumbent 4 SAE Standards News material maintains its star status for vehicle structures —and a collaborative development model. 5 Supplier Eye 20 The economics of materials selection 6 What We’re Driving Cost per pound of reduced vehicle mass is helping to drive 8 Technology Report innovation in steel, aluminum and carbon composites. 8 Why JLR is reviving the inline-six | PROPULSION 22 A step-change in the cost of CFRP 10 Studies show cold temps cripple EV range | Williams Advanced Engineering reveals secrets behind its innovations ELECTRIFICATION aimed at moving carbon fiber into the mobility mainstream. 11 Ford demos latest digital tools at flagship transmission plant | MANUFACTURING 24 Aluminum is the key “lever” Aluminum BIW and closure parts are essential for achieving 12 For bonding dissimilar materials, adhesives can both regulatory and OEM goals for improved vehicle efficiency. be a sticking point—or lack of it | MATERIALS 14 Road Ready 26 F1 streamlines for closer racing 14 Jeep revives its pickup mojo with 2020 Gladiator MOTORSPORTS TECH | AERODYNAMICS 16 New platform, chic sheetmetal for tech- In the downforce vs. turbulence battle, Formula 1 enacts technical centric 2020 Range Rover Evoque changes to rev up the on-track spectacle. 34 Product Briefs 30 Unlocking DfAM’s potential Spotlight: Test & Measurement Tools and 3D Printing/Additive Manufacturing ADDITIVE MANUFACTURING | DESIGN TOOLS A new field-based design software is supporting more widespread 38 Reader Feedback use of additive manufacturing, for faster product-development times with less rework and risk. 39 Companies Mentioned, Upcoming, Ad Index ON THE COVER 40 Q&A New grades of Advanced High Strength Steel enabled Honda R&D ‘Gladiator lingo’ with Jeep’s Elizabeth Krear and engineers to create the outstanding body structure of the 2019 Acura RDX, Pete Milosavlevski shown here in Honda’s East Liberty, Ohio, plant. Aluminum and CFRP also feature in our Lightweighting report starting on page 18. (Image: Honda) Follow us on social media Automotive Engineering®, May 2019, Volume 6, Number 5. Automotive Engineering (ISSN 2331-7639) is published in January, February, March, April, May, June, September, October, and with combined issues July/August and 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 © 2019 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 @SAEAutoMag @saeaei SAE Magazines overseas. Periodicals postage paid at New York, and additional mailing offices. POSTMASTER: Please send address changes to Automotive Engineering, P. O. Box 47857, Plymouth, MN 55447. 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 16 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 AUTOMOTIVE ENGINEERING May 2019 1 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 Jennifer Shuttleworth Bob Casey Choking on the haze of California vs. the Feds Associate Editor +1.847.223.5225 [email protected] [email protected] The term “smog” had not yet been Sacramento filed a lawsuit against EPA Lisa Arrigo Southern CA, AZ, NM, Custom Electronic Rocky Mountain States: coined when, on July 26, 1943, the first and NHTSA over the Trump administra- Products Editor Tim Powers [email protected] +1.424.247.9207 atmospheric inversion blanketed Los tion’s proposal to freeze fuel efficiency [email protected] Angeles. This alarming, eye-watering and emissions regulations at 2020 levels Contributors Northern CA, WA, OR, Western Canada: and lung-busting cloud—pollution so (about 37 mpg), rather than continuing Kami Buchholz Craig Pitcher extreme that some Angelenos thought their rise to 46.7 mpg by 2026. The fed- Detroit Editor +1.408.778.0300 Stuart Birch [email protected] it was a wartime gas attack—was a har- eral proposal also would end California’s European Editor binger for the deteriorating air quality ability to set stricter regs for the following Terry Costlow International Electronic Technologies Editor to come. The situation eventually led decade; California’s standards are fol- Europe – Central & Eastern: California to create its pioneering Motor lowed by a dozen other states and the Ian Adcock, Steven Ashley, Sven Anacker Matthew Borst, Dan Carney, Britta Steinberg Vehicle Pollution Control Board. District of Columbia. Bruce Morey, Don Sherman, +49.202.27169.11 Paul Weissler [email protected] By the mid-1960s, California had es- The existing rules were established in [email protected] tablished the first U.S. vehicle emissions 2011’s “grand bargain,” when the ARB Europe – Western: DESIGN Chris Shaw standards—which the federal govern- almost miraculously aligned itself with +44.1270.522130 Lois Erlacher [email protected] ment adopted for the Obama administra- Creative Director China: 1968-model cars. This pat- tion’s stricter federal stan- Ray Carlson Alan Ao Separate U.S. Associate Art Director +86.21.6140.8920 tern—the feds co-opting dard. Prior to this land- [email protected] California’s successful in- and California mark deal, powertrain and Japan: novations—became the vehicle planners had to SALES & Shigenori Nagatomo vehicle regs +81.3.3661.6138 model for setting vehicle engineer to two sets of MARKETING [email protected] tailpipe and evaporative mean more standards. It was a cost, Joe Pramberger South Korea: Publisher Eun-Tae Kim emissions standards in the cost, complexity complexity and compli- [email protected] +82-2-564-3971/2 Debbie Rothwell [email protected] U.S., amid stiff pushback ance nightmare. Marketing Director from automakers. and compliance While the administra- [email protected] Integrated Media If you wanted to sell tion has called on auto- Martha Tress nightmares— Recruitment Sales Manager Consultants cars in the world’s biggest makers to support the +1.724.772.7155 Angelo Danza again.
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