Design of lightweight multi-material automotive bodies using new material performance indices of thin-walled beams for the material selection with crashworthiness consideration

Currently, automotive bodies are constructed usually using a single material, e.g. steel or aluminum. Compared to single-material automotive bodies, multi-material automotive bodies allow optimal material selection in each structural component for higher product performance and lower cost. This paper presents novel material performance indices and procedures developed to guide systematic material selection for multi-material automotive bodies. These new indices enable to characterize the crashworthiness performance of complex-shaped thin-walled beams in multi-material automotive bodies according to material types. This paper also illustrates the application of these performance indices and procedures by designing a lightweight multi-material automotive body. These procedures will help to design a lightweight and affordable body favored by the automotive industry, thus to reduce fuel consumption and greenhouse gas emissions.