Application of lightweight materials toward design for sustainability in automotive component development

Abstract Vehicle lightweighting is an integral part of the overall strategies for lowering fuel consumption and exhaust emissions, regardless of the vehicle powertrain. Replacing traditionally used steel materials with new lightweight alternatives is a direct strategy that can be readily implemented by manufacturers. In addition, further weight reduction can be achieved by incorporating weight-saving component design, such as using tailor welded blanks (TWB). This chapter presents an overview of automotive lightweighting and its relationship with design for sustainability by considering the material (lightweight metal alloys), the component design strategy (TWBs), and the fabrication processes (friction stir welding and energy-efficient laser welding). The focus is made on aluminum-based alloys as a readily available alternative to existing steel-based materials, which can be used as an interim or as a long-term solution in the lightweighting strategy. A case study on a low-power laser-welded dissimilar aluminum blank is presented to show the feasibility of energy-efficient fiber laser for processing of aluminum TWB.