CASE and Weight Reduction Development of Automobile

Significance of the Topic

Automotive engineering is experiencing its greatest revolution in a century under the banner of CASE (Connected, Autonomous, Shared & Services, Electrification). Weight reduction, driven by carbon-neutrality policies and the need to extend vehicle range and efficiency, is a complementary imperative. Analytical evaluation of new materials, sensor components, and powertrain elements underpins successful innovation, ensuring safety, performance, and environmental compliance.

Objectives and Overview

This e-book presents a comprehensive suite of evaluation applications and Shimadzu’s analytical, testing, and measuring instruments designed to address the challenges of CASE mobility and vehicle weight reduction. Topics span next-generation communication modules, LiDAR and sensory systems, interior air quality, electric motor systems, battery technologies, and advanced material processing methods for composites, metals, and polymers.

Methodology and Used Instrumentation

Multiple analytical techniques are applied across CASE domains:

• X-ray computed tomography (inspeXio SMX-225CT, XSeeker 8000) for non-destructive internal inspection of PCBs, battery cells, ECUs, composite failures, and additive manufacturing defects.
• Electron probe microanalysis (EPMA-8050G) for elemental mapping at metal/composite interfaces and solder joints.
• Fourier transform infrared spectroscopy (IRTracer-100) and thermogravimetric analysis (TGA) for polymer characterization and curing kinetics.
• UV-VIS-NIR spectrophotometry (UV-2600i/2700i, SolidSpec-3700i) to evaluate optical properties of LiDAR materials and photocatalysts.
• Scanning probe microscopy (SPM-Nanoa, SPM-8100FM) for surface potential and nanoscale film observations.
• Universal testing machines (AGX-V2, HITS-X, MCT Series) for tensile, compression, bending, impact, fatigue, and high-speed mechanical tests.
• Gas chromatography-mass spectrometry (GCMS-QP2020 NX) with thermal desorption (TD-30) for VOC/SVOC analysis in vehicle interiors.
• Dynamic particle image analysis (iSpect DIA-10) and laser diffraction (SALD-2300) for particle size distribution in lubricants and powders.
• Differential scanning calorimetry (DSC-60 Plus) for polymer thermal transitions and crystallization behavior.

Main Results and Discussion

• 5G communication boards: EPMA revealed copper–polymer boundary quality; FTIR/TGA characterized thermal stability of fluorocarbon resins.
• Smartphone PCB inspection: Microfocus X-ray CT visualized internal defects and solder joint integrity.
• LiDAR sensor materials: UV-VIS-NIR data defined reflectance/transmittance performance; fNIRS mapped driver brain activation under simulated driving.
• Photocatalyst evaluation: In-situ SPM measured surface potentials during light irradiation; GC-MS quantified VOC/SVOC from interior materials per VDA278.
• Electric motor shafts: Radial forging of hollow cores improved yield strength and elongation across depths up to 15 mm.
• Composite V&V: X-ray CT-informed multiscale models enhanced accuracy of tensile and shear simulations; high-speed mechanical tests characterized strain-rate and temperature dependencies.
• Sheet metal forming: Bauschinger effect data refined springback predictions; high-speed tensile tests captured dynamic material response.
• Multi-material joining: Ultrasonic and X-ray techniques identified interfacial defects and intermetallic layers in steel–aluminum welds; EPMA mapped element diffusion.
• Additive manufacturing: CT-detected internal voids correlated with reduced fatigue life; ultrasonic fatigue testing accelerated life assessments.
• Plastic molding: PC/ABS blend ratios and mixing parameters influenced mechanical strength, yellowing, and glass-transition shifts; PLA annealing enhanced modulus and hardness via crystallization.

Practical Benefits and Applications

Shimadzu’s integrated analytical solutions enable:

• Non-destructive inspection to identify hidden defects early in design and production.
• Quantitative material characterization for simulation validation, reducing prototype iterations.
• Regulatory compliance testing for emissions, safety, and quality assurance.
• Optimization of manufacturing parameters for composites, metals, and polymers to minimize weight while ensuring durability.
• Rapid fatigue and degradation assessments to accelerate component development for EV powertrains and structural parts.

Future Trends and Opportunities

The automotive sector will evolve with:

• Advanced digital twins combining real-time data from onboard sensors and lab analytics for predictive maintenance.
• AI-driven materials design and failure analysis to shorten development cycles.
• New sustainable composites, high-performance alloys, and recyclable polymers for lighter, eco-friendly vehicles.
• Enhanced additive manufacturing quality control via in-process monitoring and machine learning defect prediction.
• Integration of high-frequency testing for 6G communication modules and next-generation sensor networks.

Conclusion

Meeting the dual challenges of CASE mobility and vehicle weight reduction demands a holistic analytical approach. Shimadzu’s extensive portfolio of imaging, spectroscopy, thermal, and mechanical instruments provides the critical data needed to innovate safely, efficiently, and sustainably in the automotive industry.

References

• Shimadzu Corporation. Solutions for CASE and Weight Reduction Development of Automobiles. 2023.