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GETTING STARTED…
1. Introduction
2. Automotive Industry Snapshot USA
Speaker: Julius Bosak, Manager Business Development Automotive, Advantage Austria Chicago
3. Automotive Industry Snapshot Canada
Speaker: Christian Lassnig, Trade Commissioner, Advantage Austria Toronto
4. Keynote: Light-Weighting Trends in Automotive USA & Canada
Speaker: Philippe Dauphin, Director General, CanmetMATERIALS, Natural Resources Canada / Government of Canada
5. Q&A
3
OVERVIEW
Market size (global): 2nd place (China 1st)14 OEMs (Original Equipment Manufacturers)Automotive exports 2018 : USD 2,6 BIL Jobs: 2,25 MIO (OEMs, suppliers, dealers) – directly connected to approx. 5 Mio. additional jobs
− Light vehicle sales: 2017 – 17,14 MIO2018 – 17,33 MIO (+0,6%) 2019* – 16,5 – 17,0 MIO (-0,5% YTD)
− Manufacturing: 2017 – 10,91 MIO 2018 – 11,18 MIO 2019* - 11,25 MIO
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INDUSTRY INDICATORS USA
Source: International Trade AdministrationSource : Wards Automotive
INDUSTRY INDICATORS USA
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Winners (Sales numbers):
Crossovers (39,6 % market share)
Pickups (16,0%)
SUV (8,5%)
Luxury Cars (6,4%)
Losers (Sales numbers):
Small Cars (12,4% market share)
Midsized Cars (10,5%)
Vans (5,3%)
Large Cars (1,2%)
Source : NADA.com
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Source : www.goodcarbadcar.net
MARKET PARTICIPANTS & CLUSTERSMarket shares (incl. Feb. 2019)
Source : US Census, NAICS codes 32621 (Tire Manufacturing) and 33630 (Motor Vehicle Parts Manufacturing)
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• Sales decreasing by 1,2% – 4%• Price increase (new vehicles)• Used vehicles readily available
• New investments in production facilities
• Continued growth in CUV/SUV segments
Risk factors:
• Section 232 Automotive tariffs
• Trade relations with China, Japan, EU and UK
• USMCA ratification process and timeline
• Continuation of Section 232 tariffs on Steel & Aluminum
TRENDS & FORECAST
Source : Center for Automotive Research
CANADA AUTOMOTIVE INDUSTRY 2018
2 million cars, light trucks and SUV‘s produced
12% share in North American production
2 million vehicles sold (excluding heavy trucks, buses etc.)
5 OEM‘s producing in Canada
big domestic suppliers: MAGNA, Linamar, Martin Rea etc.
130,000 direct jobs in production of cars and components
402,000 direct and indirect jobs
45 Universities and Colleges with Automotive Programs
2
CANADA - MARKET 2018 1,984,992 cars, SUV‘s and light trucks sold
3
Rank Vehicle Units sold
1 Ford F-Serie 145.694
2 Dodge RAM 84.854
3 Honda Civic 69.005
4 GMC Sierra 56.242
5 Toyota RAV 4 55.385
6 Chevrolet Silverado 55.334
7 Honda CR-V 54.879
8 Toyota Corolla 48.796
9 Ford Escape 43.857
10 Hyundai Elantra 41.784
PRODUCTIONIN CANADA 1-7 2019 2018: 1,999,929 units
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Manufacturer 1-7 2018 1-7 2019 % Change
FCA total 316.597 291.754 -7,85%
Chrysler 300 40.267 37.915 -5,84%
Dodge Challenger 35.693 34.845 -2,38%
Dodge Charger 58.522 59.337 1,39%
Dodge Caravan 107.373 92.380 -13,96%
Chrysler Pacifica 74.742 67.277 -9,99%
FORD total 152.939 150.445 -1,63%
Ford GT 151 149 -1,32%
Ford Edge 110.890 100.062 -9,76%
Ford Flex 14.400 14.918 3,60%
Lincoln MKT 1.945 2.581 32,70%
Lincoln MKX 25.553 32.735 28,11%
GENERAL MOTORS total 155.192 158.701 2,26%
Cadillac XTS 10.318 10.183 -1,31%
Chevrolet Impala 20.418 24.360 19,31%
Chevrolet Equinox 124.456 124.158 -0,24%
HONDA total 255.632 237.696 -7,02%
Civic 123.626 115.454 -6,61%
CRV 132.006 122.242 -7,40%
TOYOTA total 306.031 260.782 -14,79%
Toyota Corolla 115.388 20.178 -82,51%
Lexus RX 350 54.168 51.202 -5,48%
Toyota RAV4 136.475 189.402 38,78%
Total Production 1.186.391 1.099.378 -7,33%
AUTOMOTIVE SHIPMENTS AUSTRIA-CANADA 2018
Austria -> Canada 245,1 mio. EUR (20% of total exports)
Canada -> Austria 16,5 mio. EUR (4,85% of total exports)
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TRENDS IN VEHICLE LIGHTWEIGHTING
Webinar to Advantage Austria
October 9, 2019
Philippe Dauphin
Director General, NRCan
Outline
A. Natural Resources Canada
B. Trends in Vehicle Lightweighting
C. NRCan’s CanmetMATERIALS laboratory
D. Canadian R&D Ecosystem
2
3
Areas of Focus: Oil sands and heavy oil
processes (incl. tailings, water management, bioprocessing, partial upgrading, future fuels)
Tight oil & gas
Oil spill recovery and response
Flaring, venting and emissions
Devon (CanmetENERGY)
Areas of Focus: Buildings and
communities energy efficiency
Industrial processes
Clean fossil energy
Bioenergy
Renewables
Varennes (CanmetENERGY)
A. Natural Resources Canada’s CANMET labs play a key role in Clean Energy and Clean Technology Innovation
Canmet scientists are internationally-recognized experts in key energy and advanced materials R&D:
Clean electricity
Renewables and bioenergy
Fossil fuels
Energy efficiency and improved industrial processes
Materials for energy
Hamilton (CanmetMATERIALS)Ottawa (CanmetENERGY)
Areas of Focus:
Buildings energy efficiency
Industrial processes
Energy solutions for Northern and remote communities
Integration of renewable and distributed energy resources
Areas of Focus:Advanced materials for Energy efficient end-use
(transportation and industry) Energy distribution (pipelines) Clean energy production
(nuclear and bioenergy) Defence and emerging materials Non-destructive testing
certification
A Key Issue: GHG Emissions – transportation sector 2nd largest emitter
Transportation represents ¼ of Canada’s GHG emissions
CAFE Standards - by 2025 fleet standards of 54.5 MPG (4.3 L/100 km)
• Harmonized regulatory environment with U.S.
Paris target - reduce emissions by 30% by 2030 compared to 2005 levels
4
B. Trends in Vehicle Lightweighting
5
Lightweighting is key to meet emission standards
Key issue in the automotive industry
Lightweighting supports:
• Reduction in overall vehicle weight to improve fuel economy
• Meeting the evolving demands of increasingly electrified vehicle platforms
• 10% reduction in vehicle weight can lead to an 8% improvement in fuel economy
Vehicle Lightweighting & Electrification
Lightweighting & Range Anxiety:
• A lighter car requires less battery power to move, which allows it to travel farther before it needs to be recharged
• Using lightweight materials in hybrid electric, plug-in hybrid electric, and electric vehicles can offset the weight of power systems such as batteries and electric motors, improving the efficiency and increasing their all-electric range
• The use of lightweight materials could result in needing a smaller and lower-cost battery while keeping the all-electric range of plug-in vehicles constant
6
Key Lightweighting Challenges
Cost
• Using multiple materials will require manufacturers to add barriers between some metals, meaning an extra coating or material layers
• New manufacturing processes
Joining
• A key challenge is to cost-effectively join dissimilar materials while meeting increasingly stringent safety and performance standards
Materials Selection
• Although many materials show promise in reducing vehicle weight, there are pros and cons to each, ranging from production costs to property deficiencies
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Materials Selection for Lightweighting Applications
8
• Pros: High strength, stiffness, formability, and corrosion performance
• Cons: High cost, wears out stamping molds. Challenges with forming, joining, design, component processing, and behavior in harsh environments
AHSS
• Pros: Fairly mature; good stiffness, strength, and energy absorption
• Cons: Cost, joining and formability issueAl
• Pros: High stiffness and strength, compatible with existing infrastructure for stamping
• Cons: Expensive & supply. Other challenges include ductility, joining, repair, recycling, and corrosion. Rare earth additives may be needed to improve crash performance
Mg
• Pros: High strength-to-weight ratio, high-temp performance
• Cons: High cost of materials, and formability challengesTi
• Pros: High stiffness, high strength, complex shapes, and offers tremendous weight savings
• Cons: Cost and difficulty joining. Supply of sufficient amounts of fiber to meet automotive needs
CFRP
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C. Who we are: CanmetMATERIALS
A team of 70+ material scientists and technologists focused on materials for energy
165,000 ft2 facility with 107,000 ft2 dedicated to materials research
Facilities in Hamilton, Ontarioand Calgary, Alberta
Part of NRCan’s Innovation and Energy Technology Sector (IETS)
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Core Strengths: Material Science & Unique Facilities
Pilot-scale, start-to-finish materials processing:
• Materials production: casting, rolling, forming
• Enabling technologies: joining, surface treatment
Scientific knowledge of the relationships between process / microstructure / properties
• Simultaneous product and process development
• Codes and standards development for evaluation and use
What we do: CanmetMATERIALS Research Priorities
Materials for Energy End-
Use (Transportation)
Materials for Pipelines
Materials for Clean Energy
Production
Materials for
Defence
Non-Destructive
Testing Certifying
Agency
A Matrix Organization: Functional Groups
• Innovative Casting
• Advanced Materials and Processes
– Metal Forming, Physical Simulation
• Integrated Computational Materials Engineering
• Joining and Structural Performance
– Welding and Joining, Mechanical Testing
• Materials Assessment
– Corrosion Assessment, Microstructural Characterization
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Materials for Transportation – Research Areas
Vehicle Lightweighting• To reduce structural and
chassis mass through materialsdevelopments
Energy Management Materials• Novel materials that can recover as
much of the 70% of waste heat of combustion as possible
Efficient Powertrain Materials• Development of materials that enable electrification and enhance combustion
efficiency
Key Partners
Source: US DOE
Material Critical Challenges
Multi-MaterialSystems Enablers
High Volume Joining (Fusion, Mechanical,
Adhesives)
Engineered Surfaces (Corrosion, Wear, Friction)
Predictive Modeling NDE & Life MonitoringRecycling
Carbon-FiberComposites
Low-cost High-Volume Manufacturing
Low-Cost Fibers Predictive Modeling Joining, NDE, Life
Monitoring & RepairRecycling (OFFAL /
Vehicle)
AluminumLow-cost Al
Manufacturing Processes
Improved Alloys (Body/Powertrain) for
Performance & Manufacturing
Joining Mixed Al ProductsRecycling
Vehicle
Ultra High-StrengthSteels
Improved Alloys for Room Temp Forming
Weldability for Dissimilar Steel Alloys
Predictive Modeling (Formability, Crash)
MagnesiumLow Cost Feedstock, Low
Carbon Footprint Production
Galvanic Corrosion Protection
Improved Alloys for Energy Absorption
Manufacturing (Sheet and Extrusions)
Recycling
GlazingsLow Cost Feedstock for
Polymer GlazingsLow Temp Processed
Chemically Toughened GlassDurable, Scratch Resistant,
UV Resistant Coatings
Metal / Ceramic Composites
Feedstock CostCompositing Methods Powder Handling Compaction
Machining & Forming
Increasing Need for R&D
Incr
eas
ing
Imp
act
on
Re
du
cin
g V
eh
icle
Mas
sMaterial Technology Roadmap
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Mg Control Arm Material Development
• Optimization
o Die-cast preform shape for minimum material use and maximum properties
o Forging process for maximum strength
o Die-casting process for engineered properties
• Industry Partners: Multimatic, Ford U Waterloo
Materials for Transportation – Project Highlights: Lightweighting
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Thin Wall Ferrous Alloy Castings
• Development of cast iron and stainless steel for elevated-temperature applications, including automotive exhaust components – manifolds, and turbocharger housings
o Development of vacuum-mold process for thinner wall castings
o Simulation of casting process and microstructures
• Industry Partner: Wescast Industries partner
Item Weight (lb)
Casting tree 29.30
4-mm wall 6.70
3-mm wall 5.84
%weight -13%
Materials for Transportation – Project Highlights: Lightweighting
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𝑑𝑐𝑟 ≥ 4 𝑡
New Equations
AWS:
Shear Test for Measuring Weld Nugget/HAZ Strength
Resistance Spot welding technology
• Develop novel Al-steel RSW process and test method to validate the transferability to a prototype Al hood inner panel with steel reinforcements
• General Motors partner
Mini-shear Test for Measuring IMC Strength
𝑑𝑐𝑟 ≥ 4𝑡 ൗ𝜏𝐻𝐴𝑍𝑓
𝜏𝑊𝑁𝑓
1 − 𝜀
For Al−Al RSWs:
𝑑𝑐𝑟 ≥ 4𝑡 ൗ𝜏𝐻𝐴𝑍𝑓
𝜏𝐼𝑀𝐶𝑓
1 − 𝜀
For Al−steel RSWs:
Materials for Transportation – Project Highlights: Lightweighting
18
Electrical steels for traction motors• Pilot-scale production of non-oriented
electrical steel sheets
• Optimize the magnetic properties through texture and microstructure control
• Develop novel magnetic core lamination process
• Industry Partners:
D&V Electronics, Ford,
steel producers
Materials for Transportation – Project Highlights: Electrification
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National Research Council
• Lightweighting
• Composites
• Alternative propulsion
• Auto safety
University of Ontario Institute of Technology
• Climatic wind tunnel
McMaster University
• EV/HV powertrains
• Mechatronics
• Materials research
University of Windsor
• Powertrain research (electrification/ clean combustion)
University of Waterloo
• Advanced powertrains,
• Lightweighting
• Active safety
University of Western Ontario/Fraunhofer
• Project Centre for Composites Research
Innovative Vehicle Institute
• Electric/Hybrid tech
• Energy efficiency
• Vehicle intelligence
D. Canada’s Automotive R&D Ecosystem
PMG Technologies
• Vehicle test centre
• Validation
CanmetMATERIALS
• Lightweighting
• Metal processing
• Powertrain materials
University of British Columbia
• Lightweighting
• Manufacturing Automation
• Advanced materials
UPCOMING EVENTS & CONTACTS
In USA:
Julius Bosak AUSSENWIRTSCHAFT AUSTRIA AußenwirtschaftsCenter Chicago
T +1 312 644 5556 DW 204
Wwko.at/aussenwirtschaft/us
In Kanada:
Christian Lassnig AUSSENWIRTSCHAFT AUSTRIA AußenwirtschaftsCenter Toronto
T +1 416 96 73 348
Wwko.at/aussenwirtschaft/ca
Keynote Speaker:
Philippe Dauphin
Director General, CanmetMATERIALS Natural Resources Canada /
Government of Canada
T +1 905-645-0698
W https://www.nrcan.gc.ca/
USA & CANADA: ADVANCED MANUFACTURING AND NEW MATERIALS IN AUTOMOTIVE 4. – 8. November 2019, Detroit, Michigan USA/ Waterloo, Ontario Canada
FUTURE OF MOBILITY
Silicon Valley, California, 2. – 6. December 2019
Detroit/ Ann Arbor, Michigan, 9. – 10. December 2019
CONSUMER ELECTRONICS SHOW CES 8. – 11. January 2020, Las Vegas, NV
AUTOMOTIVE TECH DAYS 2020 25. – 27. March 2020, Detroit, Michigan
WCX 2020 – SAE World Congress - Advantage Austria booth, 9. – 11. April 2020 | Detroit, MI