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A D V A N C E D M A T E R I A L S & P R O C E S S E S | M A R C H 2 0 1 5
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transmission. Weight reduction in the
powertrain system also comes from a
smaller gasoline tank (four gallons less
in capacity) while maintaining the same
driving range of the lighter Fusion.
The MMLV design engine includes:
•
Aluminum block with CGI bulkhead
inserts—11.8 kg (48%) reduction
•
Aluminum connecting rods—0.7 kg
(40%) reduction
•
CF/PA oil pan—1.2 kg (40%)
reduction
•
CF/PA front cover—1.0 kg (24%)
reduction
•
CF/Al cam carrier—1.3 kg (20%)
reduction
All together, these actions reduce
the weight of the Fox engine from 88
to 72 kg—or 18%. The down-sized
1.6-liter I4 to the 1.0-liter I3 brings the
total engine system savings to 30 kg
(30%). Figure 8 illustrates the five ma-
terial substitution lightweight actions
in the engine.
Material substitution for the 6F15
six-speed automatic transmission re-
duces transmission weight to 77 kg from
the prior 6F35 transmission weight of
89 kg. Actions taken to reduce the trans-
mission weight include using a cast
magnesium case in place of the alu-
minum case, and using an aluminum
pump cover, magnesium valve body,
and a mixed material aluminum with
steel clutch hub. Combining these sav-
ings with an additional 3 kg from car-
bon fiber half shafts and lightweight CV
joints yields a 14 kg (13%) reduction in
the transmission and driveline system.
Other lightweight design actions in the
powertrain system include reduced
cooling and engine mounts for the
smaller, lighter engine.
ELECTRICAL
A 3 kg weight reduction in the
MMLV electrical system results from
switching to lightweight plastic insula-
tion (from aluminum conductors) while
an additional 6 kg are saved by replac-
ing the lead-acid battery with a lithium-
ion 12 volt starter battery as well as
minor savings in the alternator, starter
motor, and speakers. This accounts for
a 10 kg (14%) total weight reduction in
the electrical system (from 69 to 59 kg).
MATERIAL DISTRIBUTION
The MMLV design uses more alu-
minum and composites and less steel
than the Fusion. Tables 2 and 3 pres-
ent the weight savings by system and
materials.
Fig. 7 —
Cast aluminum front rotor, thermal spray process, and finished brake rotor.
Fig. 8 —
Design lightweight engine action for the 1.0-liter Fox Engine.