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					     Chrysler Group
Trends for Automotive Cast
        Materials



            Paul Bujalski
  Supervisor-Cast Metals Engineering
    DaimlerChrysler Corporation
                     Drivers
Materials
Selection            • Lower total vehicle cost
                         • Manpower
                         • Investment
                         • Materials
Trends for
Automotive           • Meet new performance requirements
Cast
                         • Customer driven
Materials
                         • Government driven

Paul Bujalski
CERP Casting Forum
May 19, 2004

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                     Density (g/cm3)
Materials            Material                 d       Material   d
Data
                     Air                      0.001   Aluminum   2.7

                     Water                    1.0     Titanium   4.5

                     Plastics                 1.1     Zinc       7.1

Trends for           Carbon fiber composite   1.3     Iron       7.2
Automotive
Cast                 Glass fiber composite    1.8     Steel      7.6

Materials            Carbon fiber             1.8     Nickel     8.8

                     Magnesium                1.8     Copper     11.3
Paul Bujalski
CERP Casting Forum   Glass Fiber              2.5     Lead       11.3
May 19, 2004

                                                                        3
                     Cost
                      Material                  Cost $/lb
Materials
                      Cast iron                 0.25
Data                  Sheet Steel               0.35
                      ADI iron                  0.5
                      Aluminum casting          0.8
                      SMC                       0.90
                      Plastics                  1.0
Trends for
                      Magnesium                 1.0
Automotive
                      Glass fiber composite     1.4
Cast
                      Aluminum Sheet            1.4
Materials
                      Carbon fiber composites   6.0

Paul Bujalski
CERP Casting Forum
May 19, 2004

                                                            4
                     Material Properties
Materials
                     Material           Tensile (Mpa)   Modulus (Gpa)
Data                 ADI iron           850             145
                     Sheet steel        500             210
                     Cast iron          250             100
                     Aluminuim sheet    275             70
                     Cast Aluminuim     275             72
                     Magnesium          230             45
Trends for           Carbon fiber       250             20
Automotive           Glass composites   200             10
Cast                 SMC                180             10
Materials            Plastics           60              1




Paul Bujalski
CERP Casting Forum
May 19, 2004

                                                                        5
                         Ranking for Structural
                         Applications
  Materials
  Data
                              FRF =        Material
                     (Tensile x Modulus)   Steel
                       (Cost x Density)    ADI iron
                                           Cast iron
  Trends for                               Cast aluminium
  Automotive                               Magnesium
  Cast                                     Aluminium sheet
  Materials                                SMC
                                           Glass fiber composite
                                           Carbon fiber composite
Paul Bujalski                              Plastics
CERP Casting Forum
May 19, 2004

                                                                    6
 Ferrous Applications
                                       Current
                                     Front Knuckle
                                     Control Arms
                                      Crankshafts
                                      Camshafts
                                     Engine Block
                                       Con Rods


Typical Ferrous Suspension        Future ?
                               Thin-Wall Steel:
         Castings        BIW Structures (B- Pillar, etc.)
                                 Chassis Assemblies
                               Austempered Ductile Iron:
                                     Crankshafts
                               Suspension Components
Ferrous Applications
                                    Current
                                  Front Knuckle
                                  Control Arms
                                   Crankshafts
                                   Camshafts
                                  Engine Block
                                    Con Rods


  Thin-Wall Cast Steel             Future ?
                               Thin-Wall Steel:
     Crossmember         BIW Structures (B- Pillar, etc.)
                             Chassis Assemblies
                           Austempered Ductile Iron:
                                 Crankshafts
                           Suspension Components
Aluminum Applications
                                     Current
                                   Front Knuckle
                                    Rear Knuckle
                                   Engine Cradle
                                    Road Wheel
                                    Engine Block
                                   Cylinder Head
                                 Transmission Case

Pacifica / 300C / Magnum             Future ?
 Rear Suspension Links         Space Frames
                           (Cast Node/Extrusion
Squeeze Casting Process        Combination)
                            BIW Closure Panels
Saves Cost over Forging BIW Structures (B- Pillar, etc.)
Magnesium Applications

                                Current
                              Steering Wheel
                             Instrument Panel
                           Steering Column Brkt.
                              Upper Mt. Brkt.
                              Pedal Sup. Brkt.

                                Future ?
           Viper                Transfer Case
  Front of Dash Support      Transmission Case
                              Liftgate, Cradles
 Super Integrated Design
                              Rear Seat Frame
 Saves Weight and Cost     Front Radiator Support
                            Oil Pan / Front Cover
                     For the Future
 Summary             • Steel will remain the dominant material.

                     • Iron will decrease but remain important.

                     • Composites will increase for low
 Trends for            volume applications.
 Automotive
 Cast
                     • Aluminum will grow and should become
 Materials
                       the number 2 material.

Paul Bujalski        • Magnesium will have high growth rate,
CERP Casting Forum
May 19, 2004           but remain below 1-3% of the vehicle.
                                                            11
Exterior Composites on the 2003 Dodge Viper
     = SMC                  = RRIM
Structural Composites on the 2003 Dodge Viper
   = Glass Fiber SMC, LMC, GMT   = Carbon Fiber SMC
                     Specific Target Areas
                     • Thin-Wall Steel Castings-Integrating
 Summary               Weldments or Fabricated Assemblies
                       into Single Component, BIW
                       Structures.

                     • Austempered Ductile Iron, More
 Trends for            Machinable ADI Grades Targeting
 Automotive            Chassis Applications.
 Cast
 Materials           • Higher Strength Aluminum Alloys,
                       2xx/7xx Series. Wrought/Forging-
                       Casting Process Combinations.
Paul Bujalski
CERP Casting Forum
May 19, 2004
                     • Magnesium Castings in Powertrain and
                                                         14
                       Chassis Applications.
 Trends for          Thank You For Your Attention.
 Automotive
 Cast
                           Any Questions?
 Materials




Paul Bujalski
CERP Casting Forum
May 19, 2004

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