INNOVATIVE SOLUTIONS FOR BODY WEIGHT REDUCTION - STRUCTURAL ADHESIVES AND FOAMS

It is no news that the automotive engineering body has been challenged to design vehicle body-in-whites (BIW) to accommodate passive and active safety systems, include functional attributes such as panorama windows, facilitate passenger access, increase loading and fuel capacity, comfort and NVH, quality and cost-benefit. The utilization of a mix of substrates within the BIW structure (Aluminum, High-Strength-Steels, and Plastics) to meet the fuel efficiency and weight reduction targets brings limitations with regards to the mechanical bonding of these different substrates and the use of metallic reinforcements in critical areas.

The application of structural adhesives and foams in cavities and joints is becoming one of the main alternatives in the design of new programs. By applying CAE simulation models to optimize the use of materials and innovative application concepts, this paper will show how these technologies can be powerful engineering tools for the OEM to comply with the above mentioned targets. This study will present cases of improved torsional stiffness, impact absorption performance, welding spots minimization, weight and cost reduction through the application of high-end materials, besides replacing environmentally harmful products currently used at the body shops