Automotive Lightweight Structures
State of the Art – Technology Review & Research Outcomes
Thursday 1 7th November 2011: IMC Auditorium, WMG, University of Warwick
Programme
08:30
Registration and coffee
09.00
Introduction and keynote presentation
D. Irving, Lead Engineer (Tata Motors European Technical Centre)
09.30
Lightweight Vehicle architecture optimisation
R. Nicholson (Coventry University)
10.00
Materials and process development for structural applications
M. Pharaoh (WMG)
10.45
Coffee and networking
11.15
Development of joining techniques for lightweight materials
D. Hughes (WMG)
12.00
Physical test programmes and outcomes
A. Reynolds (WMG)
12.45
Lunch and networking
13.30
Developing robust predictive models for composites CAE
O.Tomlin (GRM Consulting Ltd)
14.15
Lightweight seat development
M. Cromarty (Tata Motors European Technical Centre)
15.00
16.00
Workshop tour and demonstrations
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Low Carbon Vehicle Technology Project
(LCVTP)
WS 7 Lightweight Structures - Technology Review
November 17th 2011
Geraint Williams
WMG
LCVTP - Overview
15 Workstreams
Workstreams:
5 Main Industrial Partners, JLR, TMETC, ZYTEK,
RICARDO, MIRA
Battery cells & packs
Drive Motors
Power electronics
High voltage electrical distribution
Auxiliary power units
Vehicle supervisory control
Lightweight structures – WS7
Vehicle dynamics & traction control
High efficiency HVAC & system
cooling
2 Research Establishments, WMG, Coventry
University
Major Sub-contracts, Cranfield University &
University of Glamorgan
Build on previous WMG & Industry projects
Accelerate the introduction of Low Carbon Vehicle
Technologies by 4 years
£19m + £10m Private Match (2009-2014)
Reduction of parasitic losses
Waste energy & energy storage
Aerodynamic performance
HMI Engineering
Jaguar saloon beacon project
Tata beacon project
LCVTP: WS 7
Objective:
To develop materials and process technologies that will facilitate the
introduction of lightweight solutions into future electric / hybrid vehicle
programmes without compromising the overall life cycle impact.
Partners:
TMETC, MIRA, Coventry University, JLR, Ricardo
Alpha Adhesives (Associate Partner)
WS 7- Key Tasks and Deliverables
 BIW Material Technologies
Determine suitability of candidate materials and process combinations to
minimise the weight of structural automotive applications.
Provide robust design and process guidelines for the best assembly and
joining methods for a given set of material / joint interfaces.
 Lightweight seat construction
Identify and evaluate materials and process options for lightweight seat
structure concepts.
Deliverables
 Reports on current and emerging
technologies
 Lightweight EV architecture
Understand the complexities and develop a scalable architecture
model that can be applied to EV, REEV and Series Hybrid vehicles.
 Generic part and design data
 Lightweight glazing
Identify a lightweight glazing solution for each vehicle application that
optimises the optical, acoustic and thermal transmission performance.
 Design and application proposals
 Life Cycle Analysis
Ensure that materials and process technologies identified are evaluated for
their environmental performance to minimise any adverse impact.
 Roadmap to future opportunities
 Validated concepts
 Design and process guidelines
 LCA indicator
Challenges and considerations

Product application
- Availability of CAE information Structural performance
- Durability

Manufacturing implications
- Formability and joining
- Volume manufacture
- Introduction into existing facilities

Environmental impact
- Impact of alternative material on Life Cycle CO2 Volatile Organic Compounds
- LCA methodologies
Automotive Lightweight Structures
State of the Art – Technology Review & Research Outcomes
Thursday 1 7th November 2011: IMC Auditorium, WMG, University of Warwick
Programme
08:30
Registration and coffee
09.00
Introduction and keynote presentation
D. Irving, Lead Engineer (Tata Motors European Technical Centre)
09.30
Lightweight Vehicle architecture optimisation
R. Nicholson (Coventry University)
10.00
10.45
11.15
12.00
12.45
Materials and process development for structural applications
M. Pharaoh (WMG)
Coffee and networking
Development of joining techniques for lightweight materials
D. Hughes (WMG)
Physical test programmes and outcomes
A. Reynolds (WMG)
Lunch and networking
13.30
Developing robust predictive models for composites CAE
O.Tomlin (GRM Consulting Ltd)
14.15
Lightweight seat development
M. Cromarty (Tata Motors European Technical Centre)
15.00
16.00
Workshop tour and demonstrations
C
l
o
s
e