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COSMA

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Angelo Del Grosso
Angelo Del Grosso

Cosma International, in partnership with Ford and the DOE, developed a multi-material lightweight vehicle concept called the MMLV that achieved a 23.3% weight reduction compared to the Ford Fusion. Through reengineering the body, closures, and chassis to use various grades of aluminum, magnesium, and high-strength steels joined with new technologies, the MMLV met all testing requirements while maintaining performance, durability, and safety. The substantial fuel economy and environmental benefits of these lightweighting approaches could have large-scale impacts if implemented more broadly in future vehicle production programs.

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Multi Material Lightweight Vehicle (MMLV) Cosma International, the metalforming group of Magna, in cooperation with Ford Motor Company and the US Department of Energy, has developed a multi-material lightweight vehicle concept that effectively achieves a 23.3% weight reduction compared to the current production Ford Fusion. Cosma International Summary The substantial environmental and fuel economy benefits gained by taking this initiative into future production programs would be impactful on a global scale. Through the strong partnership between Cosma, Ford, and the DOE, it has been demonstrated and proven that effective lightweight alternatives exist today. Engineering Cosma reengineered the body-in-white, closures and chassis structure incorporating new joining technologies and an optimal mix of materials including several grades of wrought and cast aluminum, magnesium, and high strength steels. Vehicle performance parameters, durability, and safety of the production vehicle were maintained. Test / Validate Going beyond design and build, Cosma participated in all aspects of vehicle testing, no different than any production intent vehicle. All crash, durability, and performance testing results met or exceeded expectations. Concept and design become reality. Concept and design become reality. Prototype Once the vehicle design was complete, Cosma fully prototyped and built eight complete and drivable vehicles to be crashed and tested. Production intent materials and processes were used to ensure these lightweight concepts would meet the standards required for future high volume production. Innovative processes such as high pressure vacuum die casting, hot stamping, extruded aluminum, structural adhesive, and riveting were used in the areas of the vehicle where they provided the maximum benefit.
Vehicle Subsystem 2013 Fusion (kg) MMLV Mach I (kg) Mass Reduction (kg) Body Exterior and Closures 594 456 138 Powertrain 340 267 73 Chassis 350 252 97 Body Interior and Climate Control 206 161 45 Electrical 69 59 10 Total Vehicle 1559 1195 363 nnovation iconsMagna Innovation icons The MMLV points the way to a more sustainable future. We at Magna are working diligently to make these lightweight technologies affordable for high volume production. Swamy Kotagiri, Chief Technology Officer, Magna Baseline* MMLV Concept Vehicle* Weight Save Compared to 2013 Fusion 23.3% Steel Aluminum Greener. Lighter. Hot Stamping For more information contact: MMLV@magna.com 16% reduction in global warming potential and total primary energy. *Body-in-white only CSMMMLV-SAEV2 The information, data, or work presented herein was funded in part by the Office of Energy Efficiency and Renewable Energy (EERE), U.S. Department of Energy, under Award Number DE-EE0005574.

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COSMA

  • 1. Multi Material Lightweight Vehicle (MMLV) Cosma International, the metalforming group of Magna, in cooperation with Ford Motor Company and the US Department of Energy, has developed a multi-material lightweight vehicle concept that effectively achieves a 23.3% weight reduction compared to the current production Ford Fusion. Cosma International Summary The substantial environmental and fuel economy benefits gained by taking this initiative into future production programs would be impactful on a global scale. Through the strong partnership between Cosma, Ford, and the DOE, it has been demonstrated and proven that effective lightweight alternatives exist today. Engineering Cosma reengineered the body-in-white, closures and chassis structure incorporating new joining technologies and an optimal mix of materials including several grades of wrought and cast aluminum, magnesium, and high strength steels. Vehicle performance parameters, durability, and safety of the production vehicle were maintained. Test / Validate Going beyond design and build, Cosma participated in all aspects of vehicle testing, no different than any production intent vehicle. All crash, durability, and performance testing results met or exceeded expectations. Concept and design become reality. Concept and design become reality. Prototype Once the vehicle design was complete, Cosma fully prototyped and built eight complete and drivable vehicles to be crashed and tested. Production intent materials and processes were used to ensure these lightweight concepts would meet the standards required for future high volume production. Innovative processes such as high pressure vacuum die casting, hot stamping, extruded aluminum, structural adhesive, and riveting were used in the areas of the vehicle where they provided the maximum benefit.
  • 2. Vehicle Subsystem 2013 Fusion (kg) MMLV Mach I (kg) Mass Reduction (kg) Body Exterior and Closures 594 456 138 Powertrain 340 267 73 Chassis 350 252 97 Body Interior and Climate Control 206 161 45 Electrical 69 59 10 Total Vehicle 1559 1195 363 nnovation iconsMagna Innovation icons The MMLV points the way to a more sustainable future. We at Magna are working diligently to make these lightweight technologies affordable for high volume production. Swamy Kotagiri, Chief Technology Officer, Magna Baseline* MMLV Concept Vehicle* Weight Save Compared to 2013 Fusion 23.3% Steel Aluminum Greener. Lighter. Hot Stamping For more information contact: MMLV@magna.com 16% reduction in global warming potential and total primary energy. *Body-in-white only CSMMMLV-SAEV2 The information, data, or work presented herein was funded in part by the Office of Energy Efficiency and Renewable Energy (EERE), U.S. Department of Energy, under Award Number DE-EE0005574.