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Energy efficiency and clean, renewable energy will mean a stronger economy, a cleaner environment, 

and greater energy independence for America. Working with a wide array of state, community, industry, and 

university partners, the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy 

invests in a diverse portfolio of energy technologies.

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Acknowledgement

We would like to express our sincere appreciation to QSS Group, Inc., Oak Ridge National 

Laboratory, and Argonne National Laboratory for their technical and artistic contributions 

in preparing and publishing this report. 

In addition, we would like to thank all the participants for their contributions to the programs and all the authors who prepared the project abstracts that comprise this report. 
U.S. Department of Energy 

 Office of FreedomCAR and Vehicle Technologies 

 1000 Independence Avenue S.W. 

 Washington, DC 20585-0121 

FY 2005 

Progress Report for High Strength Weight Reduction 

Materials 

Energy Efficiency and Renewable Energy 

Office of FreedomCAR and Vehicle Technologies 

Advanced Materials Technologies 

Edward Wall Program Manager, OFCVT 

Rogelio Sullivan Advanced Materials Technologies Team Leader 

James Eberhardt Chief Scientist 

August 2006 

High Strength Weight Reduction Materials FY 2005 Annral Report 

CONTENTS

1. INTRODUCTION............................................................................................................................. 1

2. MATERIALS DEVELOPMENT .................................................................................................... 3 

A. Advanced Materials for Friction Brakes..................................................................................... 3 

B. Integrated Approach for Development of Energy-Efficient Steel Components for 

Heavy Vehicle and Transportation Applications........................................................................ 8 

C. Development of Technologies for the Application of Magnesium Metal Matrix 

Composites for Heavy Vehicles ................................................................................................. 16 

D. Lightweight Functional Composite Materials ............................................................................ 25 

3. MATERIALS PROCESSING TECHNOLOGIES....................................................................... 31 

A. Laser Glazing and Friction Stir Processing of Materials to Reduce Friction ............................. 31 

B. Development of an Advanced Squeeze Casting Process for the Production of 

High-Integrity Truck Components ............................................................................................. 38 

C. Wrought Magnesium Alloy/Process Development .................................................................... 43 

D. Thermomechanical Processing of Ti and Ti-6Al-4V Sheet and Plate from

Low Cost Powders...................................................................................................................... 50 

E. Counter Gravity (Hitchiner) and Pressure Assisted Lost Foam Magnesium Casting ................ 57 

4. ENABLING TECHNOLOGIES...................................................................................................... 65 

A. Joining of Advanced Materials by Plastic Deformation............................................................. 65 

B. Rapid, Low-Cost Tooling Development..................................................................................... 72 

C. Improved Friction Tests for Engine Materials............................................................................ 75 

D. Equal Channel Angular Extrusion Processing of Alloys for Improved 

 Mechanical Properties ................................................................................................................ 79 

E. Attachment Techniques for Heavy Truck Composite Chassis Members ................................... 86 

F. Laser Texturing of Propulsion Materials.................................................................................... 95 

G. Friction Stir Joined Aluminum Sheet Materials for Heavy Vehicle Cab Structures .................. 103 

H. Friction Stir Joining and Processing of Advanced Materials Including MMCs......................... 112 

I. Friction Stir Welding and Processing of Advanced Materials ................................................... 122 

J. Portfolio Analysis for Lightweight Materials............................................................................. 135 

K. Inventory of Heavy-Duty Truck Lightweighting Candidates..................................................... 137 

L. Basic Studies of Ultrasonic Welding for Advanced Transportation Systems ............................ 143 

M. Effects of Highway Ice-Clearing Treatments on Corrosion of Heavy Vehicle 

Materials and Components ......................................................................................................... 153 

5. LIGHTWEIGHT VEHICLE STRUCTURES ............................................................................... 161 

A. Lightweight Trailer-Liburndas Project....................................................................................... 161 

B. Application of Superplastically Formed Aluminum for Truck Body Panels ............................. 166 

C. Advanced Composite Support Structures................................................................................... 169

D. New-Generation Frame for Pickup/Sport Utility Vehicle Application ...................................... 177 

E. Advanced Superplastic Forming Development for Heavy Vehicle Structures .......................... 179 

F. Development of Magnesium for Heavy Vehicle Powertrain Components ................................ 184 

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FY 2005 Annual Report High Strength Weight Reduction Materials 

CONTENTS (CONT.) 

G. Lightweight Stainless Steel Bus Frame—Phase III.................................................................... 188 

H. Side Impact Analysis of a Lightweight Stainless Steel Bus Structure........................................ 193 

I. Stainless Steel Bus Structure – Manufacturing Cost Analysis ................................................... 198 

6. APPLICATION OF INNOVATIVE MATERIALS ...................................................................... 203 

A. Carbon Fiber SMC for Class 8 Vehicle Hoods .......................................................................... 203 

B. Application of Carbon Fiber for Large Structural Components................................................. 207 

C. Hybrid Composite Materials for Weight-Critical Structures...................................................... 213 

D. Advanced Composite Structural Cab Components .................................................................... 216 

E. Advanced Composite Structural Chassis Components............................................................... 223 

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