General Motors Lightweighting Strategy Dr. Paul E. Krajewski Global - - PDF document

General Motors Lightweighting Strategy

• Dr. Paul E. Krajewski

Global Mass Integration and Strategy

General Motors Company

Vehicle Lightweighting

Global CO2 / Fuel Economy requirements will necessitate significant vehicle lightweighting. Expect 1-2 TWC reduction in mass for most vehicles. Lightweight materials will play a significant role in enabling mass reduction.

GM Has Long History of Lightweight Materials Innovation

1961 Magnesium Instrument Panel 1953 Fiberglass Body Panels 1969 Chevy Aluminum Big Block

Recent Lightweight Materials Innovations

Press Hardened Steel Aluminum Shock Towers Magnesium Decklid Aluminum Doors Aluminum Body Structure Carbon Fiber Hood

Cost Down Cost Up Baseline

Customer Requirements Material Selection

5% 10% 20% 30% 40%

Percent Below Industry Regression Line

0%

Material Utilization

Premium Matls & Mfg Processes

(Applied Independent of Material type to Minimize Mass & Cost) PHS + Aluminum AHSS/UHSS/PHS CFRP + Aluminum + Magnesium

Efficient Fundamentals

Lightweighting Strategy

Right Sizing

Means understanding what the customer expects. Delivering a vehicle that exceeds their expectations Vehicle must be priced / sized consistent with competition Provide best customer driving experience low operating costs and outstanding quality.

Customer Focus Camaro Z28

increase speed on the Camaro Z28, Chevrolet jettisoned just about everything that added weight but wasn't critical. That includes carpeting in the trunk, insulation and every speaker but one Vehicle mass reduced by 140 kg.

Understanding the Customer Efficient Fundamentals

Topology Optimization Material Selection Gage Selection Material Utilization Independent of material type or vehicle platform

ATS

Every Gram, Every Engineer, Every Day

2.8 kg

eliminated

ATS Material Utilization

(Lightening holes & scalloped flanges)

Premium Materials

Strategic Application Efficient Design Cost Effective Manufacturing Enabled

CTS Aluminum Door

Saved 18kg/vehicle from the most mass efficient steel door systems in the industry.

Summary

All vehicles will required significant lightweighting to meet post 2020 CO2 / FE targets. Lightweighting will be achieved through a combination of efficient fundamentals and premium lightweight materials. Need strategic focus to ensure that the enterprise and supply base are ready for these materials.