Conventional vehicle design is continually being pushed by consumers and regulations to reach higher level of fuel efficiency and system performance. New methods such as use of alternative structural materials and structural optimization are being utilized heavily in the automotive industry. Currently, materials such as advanced composites, polymers, aluminum and magnesium are all being considered as candidates for alternatives to conventional steel parts to help meet lightweight performance targets.While topology optimization has proven to be a powerful in many case studies for automotive light weighting studies, it is currently constrained for use with one material in the optimization algorithm. Multi-material topology optimization (MMTO) methods presented in this paper demonstrate the tools capability to optimize material selection simultaneously alongside material layout for a given design space and desired weight target. Extensions to MMTO methodology demonstrate the ability to manipulate the mathematical problem statement for optimization in order to achieve a desired amount of each material in the final solution.Discussed in this paper is the application of MMTO to an automotive case study and the examination of…

As conventional vehicle design is adjusted to suit the needs of all-electric, hybrid, and fuel-cell powered vehicles, designers are seeking new methods to improve system-level design and enhance structural efficiency; here, multi-material optimization is suggested as the leading method for developing these novel architectures. Currently, diverse materials such as composites, high strength steels, aluminum and magnesium are all considered candidates for advanced chassis and body structures. By utilizing various combinations and material arrangements, the application of multi-material design has helped designers achieve lightweighting targets while maintaining structural performance requirements. Unlike manual approaches, the multi-material topology optimization (MMTO) methodology and computational tool described in this paper demonstrates a practical approach to obtaining the optimum material selection and distribution of materials within a complex automotive structure.Discussed in this paper is the application of MMTO and the examination of results obtained from 1-material, 2-material and 3-material optimization. First the effect of number of materials in the design and its effect on design performance is analyzed. Next individual material combinations and their effect on the final design performance are…

This specification covers an aluminum alloy in the form of clad sheet 0.006 to 0.249 inch (0.015 to 6.32 mm) inclusive, in thickness (see 8.5).

This specification covers an aluminum alloy in the form of rolled or cold finished bars, rods, and wire up to 6.000 inches (152.40 mm) in nominal diameter or least nominal dimension (see 8.6).

This specification covers an aluminum alloy in the form of plate 0.250 to 4.000 inch (6.35 to 101.60 mm) inclusive, in thickness (see 8.6).

This specification covers a nickel in the form of round wire and rectangular ribbon.

This specification covers an aluminum alloy in the form of seamless, drawn tubing having a nominal wall thickness of 0.120 to 0.400 inch (3.00 to 10.00 mm) inclusive (see 8.4).