SAE

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Chrysler Group Trends for Automotive Cast
Materials
Paul Bujalski Supervisor-Cast Metals
EngineeringDaimlerChrysler Corporation
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Drivers
Materials Selection Trends for Automotive Cast
Materials

• Lower total vehicle cost
• Manpower
• Investment
• Materials
• Meet new performance requirements
• Customer driven
• Government driven

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Density (g/cm3)
Materials Data Trends for Automotive Cast
Materials
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Cost
Materials Data Trends for Automotive Cast
Materials
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Material Properties
Materials Data Trends for Automotive Cast
Materials
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Ranking for Structural Applications

Materials Data Trends for Automotive Cast
Materials
FRF (Tensile x Modulus) (Cost x Density)
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Ferrous Applications
Current
Front Knuckle Control Arms Crankshafts Camshafts
Engine Block Con Rods
Future ?

• Thin-Wall Steel
• BIW Structures (B- Pillar, etc.)
• Chassis Assemblies
• Austempered Ductile Iron
• Crankshafts
• Suspension Components

Typical Ferrous Suspension Castings
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Ferrous Applications
Current
Front Knuckle Control Arms Crankshafts Camshafts
Engine Block Con Rods
Future ?

• Thin-Wall Steel
• BIW Structures (B- Pillar, etc.)
• Chassis Assemblies
• Austempered Ductile Iron
• Crankshafts
• Suspension Components

Thin-Wall Cast Steel Crossmember
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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
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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
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For the Future
Summary Trends for Automotive Cast Materials

• 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.

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Exterior Composites on the 2003 Dodge Viper
SMC RRIM
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Structural Composites on the 2003 Dodge Viper
Glass Fiber SMC, LMC, GMT Carbon
Fiber SMC
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Specific Target Areas

• 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.

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