2010 annual progress report Lightweighting Material For more information DOE/EE-0577 January 2011 1-877-EERE-INFO (1.877.337.3463) Printed with a renewable-source ink on paper containing eere.energy.gov at least 50% wastepaper, including 10% post consumer waste. Contents A. Acronyms and Abbreviations Acronyms and Abbreviations.............................................................................................................................................A-1 1. Introduction Introduction.........................................................................................................................................................................1-1 2. Automotive Metals A. Processing and Manufacturability - Oak Ridge National Laboratory..............................................2-1 B. Processing and Manufacturability - Pacific Northwest National Laboratory..................................2-8 C. Modeling and CMS - Oak Ridge National Laboratory....................................................................2-31 D. Modeling and Computational Material Science - Pacific Northwest National Laboratory............2-35 E. Southern Regional Center For Lightweight Innovative Designs - Mississippi State University.....2-39 F. Multi-material Enabling - Oak Ridge National Laboratory.............................................................2-67 G. Multi-Material Enabling - Pacific Northwest National Laboratory.................................................2-80 H. A Study of the Effects of Microstructure on the Mechanical Properties and Failure Mechanisms of Advanced High-Strength Steels.......................................................................................................2-89 I. Development of Nano-Acicular Duplex Steels...............................................................................2-95 3. Polymer Composites A. Polymer Composite Development - Pacific Northwest National Laboratory..................................3-1 B. Polymer Composite Development - Oak Ridge National Laboratory............................................3-10 C. Low Cost Carbon Fiber Development - Oak Ridge National Laboratory......................................3-28 D. Carbon Fiber Technology Center.................................................................................................3-50 4. USMP Cooperative Research A. Automotive Composites Consortium.............................................................................................4-1 B. Automotive Metals Division - U.S. Automotive Materials Partnership........................................4-16 C. Auto/Steel Partnership - U.S. Automotive Materials Partnership................................................4-57 D. Nondestructive Evaluation Steering Committee - U.S. Automotive Materials Partnership.........4-85 E. Multi-Material Vehicle - U.S. Automotive Materials Partnership...................................................4-91 i 5. Recyclimg A. Recycling End-of-Life Vehicles Of The Future - Argonne National Laboratory..............................5-1 6. Crosscutting A. Cost Modeling - Oak Ridge National Laboratory............................................................................6-1 B. Safety Data and Analysis - Lawrence Berkeley National Laboratory.............................................6-6 ii ALM 2010 Acronyms and Abbreviations µm micrometer (micron) 1D one dimensional 2D two dimensional 3D three dimensional A ABS acrylonitrile-butadiene-styrene ACC Automotive Composites Consortium ACC-PD American Chemistry Council–Plastics Division ACTS Advanced Concepts Test Stand AET Applied Engineering Technologies, Inc. AHSS advanced high-strength steel Al aluminum AMD Automotive Metals Division AMI Autodesk Moldflow Insight ARL U.S. Army Research Laboratory ARD-RSC anisotropic rotary diffusion–reduced strain closure A/SP Auto/Steel Partnership ASTM American Society for Testing and Materials B bcc body centered cubic BIW body-in-white BN boron nitride C C carbon CA cellular automaton CAD computer aided design CAE computer aided engineering CALPHAD CALculated PHAse Diagrams CAVS Center for Advanced Vehicular Systems CC continuous cast A-1 CCD charge-coupled device CeCC cerium based conversion coating CF carbon fiber CFSL carbon fiber semi-production line CFTC Carbon Fiber Technology Center CLSM confocal laser scanning microscope CMH-17 Composite Materials Handbook 17 CNW cellulose nanowhisker CMS computational materials science CO2 carbon dioxide CPI Composite Products, Inc. CRO Community Reuse Organization CSUV car-based SUV CT computed tomography CUV crossover utility vehicle CY calendar year D DCT dual clutch transmission DFT discrete Fourier transform DI direct injection DIC digital image correlation DLFT direct injected LFT DMG (coupled) elasto-viscoplastic-damage DOE U.S. Department of Energy DOHC dual overhead camshaft DOHV dual overhead valves DP dual phase DRIFT Direct Reinforcement Fabrication Technology DSC differential scanning calorimetry E EBSD electron backscatter diffraction e-coat/coating electrocoat/electrocoating A-2 EC eutectic constituent ED extruded direction EDS energy dispersive spectroscopy EHF electrohydraulic forming ELV end-of-life vehicle EMTA Eshelby-Mori-Tanka EMP electromagnetic pump EPA US Environmental Protection Agency EPFL École Polytechnique Fédérale de Lausanne EPMA electron probe microanalysis ESEM environmental scanning electron microscope ESPEI extensible, self-optimizing magnesium phase equilibrium infrastructure ETD extruded transverse direction ETW equivalent test weight F FARS Fatality Analysis Reporting System fcc face centered cubic Fe iron FE finite element FEA finite element analysis FEM finite element modeling FFI full frontal impact FGPC Future Generation Passenger Compartment FISIPE Fibras Sinteticas de Portugal S.A. FLCA front lower control arm FLD forming limit diagram FM flexural modulus FPI fluorescent penetrant inspection fps frames per second FRPMC fiber-reinforced polymer-matrix composite FS flexural structure FSSW friction stir spot weld/welding FSW friction stir welding A-3 FTIR Fourier transform infrared spectroscopy FY fiscal year G GBCE grain boundary cohesion energy GCWR gross combined weight rating Gen generation GHG greenhouse gas GM General Motors GMAW gas-metal arc welding GSF generalized stacking fault GVWR gross vehicle weight rating H H&E hematoxylin and eosin HAZ heat-affected zone hcp hexagonal close packed HDG hot-dip-galvanized HP high pressure HSS high-strength steel I I4 inline (architecture), four cylinders IACS International Annealed Copper Standard ICAF intergranular corrosion area fraction ICME Integrated Computational Materials Engineering IISI International Iron and Steel Institute I/M inspection and maintenance IR infrared ISF intrinsic stacking fault ISV internal state variable A-4 K K–PhD kindergarten through doctoral level KR kriging L LB lattice Boltzmann LBNL Lawrence Berkeley National Laboratory LCA life-cycle analysis LDH limiting dome height LCCF low cost carbon fiber LENS laser engineered net shaping LFT long fiber thermoplastic LGK Lipton-Glickson-Kurz LM Lightweight Materials LP low pressure LPPM low pressure permanent mold (casting process) LSEM large strain extrusion machining LSTC Livermore Software Technology Corporation M MCTS Materials Compatibility Test Stand MD molecular dynamics MEAM modified embedded atom method MEARS Mass Efficient Architecture for Roof Strength MFED Magnesium Front End Design and Development MFERD Magnesium Front End Research and Development MIG metal inert gas Mg magnesium MgO magnesium oxide Missouri S&T Missouri University of Science and Technology MMV multi-material vehicle Mn manganese MSF multistage fatigue MSST Mississippi State University A-5 MTR1 Multiple Tow Reactor 1 MY model year N NA naturally aspirated NASS GES National Automotive Sampling System General Estimates System NCMS National Center for Manufacturing Science NDE nondestructive evaluation NHTSA National Highway Traffic Safety Administration NIST National Institute of Standards and Technology NLA nonlinear analysis NPSS nanosize precipitate strengthened steel NSF National Science Foundation NSP nonlinear strain path NTRC National Transportation Research Center NVH noise, vibration, and harshness O OEM original equipment manufacturer OFI offset frontal impact OHV overhead valve OM optical microscopy ORNL Oak Ridge National Laboratory OU Oakland University OVT Office of Vehicle Technologies (DOE) P PAN polyacrylonitrile PB paint-baked PCB polychlorinated biphenyl PCBN polycrystalline cubic boron nitride PE polyethylene PEL precursor evaluation line PEO polyethylene oxide A-6 PET polyethylene terephthalate PFI port fuel injection phr parts per hundred parts resin PI principal investigator PFSL precursor fiber semi-production line PM powder metallurgy PMC polymer-matrix composite PNNL Pacific Northwest National Laboratory POD probability of detection PP polypropylene PPF pulse pressure forming PS polystyrene PSC Project Steering Committee PSHPB polymeric split Hopkinson pressure bar PTC project technical committee R R&D research and development RBF radial basis function RD rolling direction RI resonant inspection RSW resistance spot welding RT radiographic testing RTM resin transfer molding RUC representative unit cell S S Sulfer SABIC-IP SABIC Innovative Plastics SBSS short beam shear strength SCC stress corrosion cracking SCRLID Southern Regional Center for Lightweight Innovative Designs SDS state data system SEA specific energy absorption A-7