Hybrid Shock Absorber
Case Study 1, led by the worldwide automotive supplier TENNECO, consisted in the development of an hybrid shock absorber.
The concept was to develop a composite loop of the shock absorber bottom and integrate it with the shock absorber body.
The challenge was to achieve a strong and sealed connection between the loop and the body.
The advantage sought was to reduce the shock absorber weight and simplify the production process.
The resulted on the connection strength were very promising and the prototype allowed to achieve 16% Weight Save and estimate a 18% Life Cycle Cost Decrease.
Hybrid Brake Pedal
Case Study 2, led by TOOLPRESSE, a Portuguese SME, consisted in the development of a hybrid brake pedal.
The concept was to develop a composite brake pedal lighter and saver for the driver.
In order to overcome some bending problems of an full composite part and designed an hybrid part that combined the rigidity of the metal with the lightweight of the composite. Also the new design avoided sharp edge resulting in a safer brake pedal in case of impact.
The new brake pedal allowed to achieve 17% Weight Save and estimate a 61% Life Cycle Cost Decrease.
Hybrid Crash Absorber
The third Case Study was led by Regeneracija, a Slovenian SME, consisted in the development of an hybrid Crash Absorber.
The concept was to develop a composite Crash Absorber significantly lighter and stronger.
The solution to answer to the Crash Absorber technical requirements drove us to an hybrid part once its needed to connect the crash absorber with the car steel body and also it should be easy to replace.
The new Crash Absorber allowed achieving 50% Weight Save and estimate with a similar Life Cycle Cost comparing to the traditional steel Crash Absorbers.
Optimization of Joining Processes for New Automotive Metal-Composite Hybrid Parts
Collaborative Project - FP7-2013-NMP-ICT-FOF(RTD)
GA nr.609039
