Highly integrated lightweight solutions for the vehicle structure and new concepts for crash-energy-absorption

Abstract

Highly integrated lightweight solutions for the vehicle structure and new concepts for crash-energy-absorption The decrease of the CO2-emission and the protection of resources is a priority objective the automobile industry has to challenge in present and future. The reduction of the vehicle mass is very important in order to reach new milestones in reducing fuel consumption and emissions. Steel structures still shows lightweight potential. But even more attractive potential for lightweight body in white structures could be realised by multi material design. The DLR (German Aerospace Center) Institute of Vehicle Concepts and the Meridian Company will show the efficiency and cost effectiveness of lightweight construction by examples of highly integrated casted magnesium parts. Beside the examples of cast parts in magnesium design the DLR will present innovative concepts to improve the crash energy absorption in front end structures. According to different crash standards a lot of requirements have to be fulfilled within this particular area of the vehicle structure. Static loads and the limitation of intrusion and deceleration need to be harmonised. The potential of alternative effects with optimised geometries and new steel alloys (e.g. with higher strain level) will be discussed within the presentation.