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DOE/EE-0577 January 2011 Printed with a renewable-source ink on paper containing at least 50% wastepaper, including 10% post consumer waste.

annual progress report2010

Lightweighting Material

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..................................2-8C. Modeling and CMS - Oak Ridge National Laboratory....................................................................2-31 D. Modeling and Computational Material Science - Pacific Northwest National Laboratory............2-35E. Southern Regional Center For Lightweight Innovative Designs - Mississippi State University.....2-39F. Multi-material Enabling - Oak Ridge National Laboratory.............................................................2-67G. Multi-Material Enabling - Pacific Northwest National Laboratory.................................................2-80H. A Study of the Effects of Microstructure on the Mechanical Properties and Failure Mechanisms of

Advanced High-Strength Steels.......................................................................................................2-89I. Development of Nano-Acicular Duplex Steels...............................................................................2-95

3. Polymer Composites

A. Polymer Composite Development - Pacific Northwest National Laboratory..................................3-1B. Polymer Composite Development - Oak Ridge National Laboratory............................................3-10C. Low Cost Carbon Fiber Development - Oak Ridge National Laboratory......................................3-28D. Carbon Fiber Technology Center.................................................................................................3-50

4. USMP Cooperative Research

A. Automotive Composites Consortium.............................................................................................4-1B. Automotive Metals Division - U.S. Automotive Materials Partnership........................................4-16C. Auto/Steel Partnership - U.S. Automotive Materials Partnership................................................4-57D. Nondestructive Evaluation Steering Committee - U.S. Automotive Materials Partnership.........4-85E. 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............................................................................6-1B. Safety Data and Analysis - Lawrence Berkeley National Laboratory.............................................6-6

ii

ALM 2010 Acronyms and Abbreviations m micrometer (micron)

1D one dimensional

2D two dimensional

3D three dimensional

A ABS acrylonitrile-butadiene-styrene

ACC Automotive Composites Consortium

ACC-PD American Chemistry CouncilPlastics 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 diffusionreduced 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 cole Polytechnique Fdrale 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 KPhD 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 polychlorin