CASE and Weight Reduction Development of Automobile

Importance of the Topic

Innovation in Connected, Autonomous, Shared & Services, and Electrification (CASE) mobility, combined with systematic weight reduction, underpins the next major revolution in the automotive industry. These trends address global carbon neutrality goals, enhance safety and comfort, and improve vehicle efficiency and performance.

Objectives and Overview of the Study

This e-book surveys evaluation applications and Shimadzu’s analytical, testing, and measurement instruments tailored to key challenges in achieving CASE functions (5G connectivity, LiDAR performance, shared-vehicle hygiene, high-output electric systems) and reducing vehicle weight via advanced materials and processes.

Methodology

A diverse set of analytical and testing techniques is employed across multiple domains:

• Microstructure and element mapping by electron probe microanalysis (EPMA)
• Spectroscopy and thermal analysis (FTIR, TGA, UV-Vis-NIR, DSC)
• Non-destructive internal imaging by X-ray CT and X-ray fluoroscopy
• Mechanical testing under static and dynamic loads (universal testers, high-speed impact, ultrasonic fatigue)
• Surface and nanoscale measurements via scanning probe/atomic force microscopy (SPM/AFM)
• Volatile organic compound (VOC) analysis by GC-MS and thermal desorption
• Real-time physiological monitoring with functional near-infrared spectroscopy (fNIRS)
• Particle size and morphology through laser diffraction and dynamic image analysis

Used Instrumentation

• EPMA-8050G electron probe microanalyzer
• FTIR spectrophotometers (IRTracer-100, IRXross)
• TGA and DSC systems (TGA-50, DSC-60 Plus)
• UV-Vis-NIR spectrophotometers (SolidSpec-3700i, UV-2600i)
• Microfocus X-ray CT (inspeXio SMX-225CT, Xslicer SMX-6010)
• Precision universal testers (AUTOGRAPH AGX-V2)
• High-speed impact testers (HITS-X Series)
• SPM/AFM systems (SPM-Nanoa, SPM-8100FM)
• GCMS-QP2020NX with TD-30 thermal desorption
• Laser diffraction (SALD-2300) and dynamic image analyzers (iSpect DIA-10)
• Functional NIRS (LABNIRS)

Main Results and Discussion

• Connected: EPMA and FTIR/TGA characterized high-frequency PCB insulators and fluorocarbon resin stability; microfocus CT visualized defects in 5G circuit boards.
• Autonomous: UV-Vis-NIR assessed LiDAR optical components; fNIRS evaluated driver brain activation under simulated driving conditions.
• Shared & Services: SPM mapped photocatalyst surface potentials; VOC/SVOC emissions from interior materials were quantified per VDA278.
• Electrification – Electric Systems: Radial forging of hollow shafts improved mechanical strength deep into the material; CT and mechanical tests optimized motor components and lubricants.
• Electrification – Batteries: AFM revealed electrode microstructure in solid-state cells; CT imaged cylindrical cell internals; DSC, compression, and gas analyses evaluated thermal and degradation behaviors.
• Electrification – Inverters: X-ray CT and fluoroscopy non-destructively inspected ECU internals and solder joints; fatigue and mechanical tests validated reliability under vibration and thermal stress.
• Weight Reduction – Composites: Multiscale CAE model V&V was enhanced using CT-derived geometry and mechanical data; impact and failure analyses clarified rate-dependent properties and cracking mechanisms.
• Weight Reduction – Sheet Metal: Bauschinger effect measurements improved springback predictions; high-speed tensile tests evaluated strain-rate effects on advanced steels.
• Weight Reduction – Multi-Materials: Ultrasonic flaw detection and EPMA characterized joint quality in steel-aluminum friction stir welds; mechanical tests correlated intermetallic layers and defects with strength.
• Weight Reduction – Additive Manufacturing: CT quantified internal defects in 3D-printed titanium; ultrasonic fatigue testing linked defect shape and location to crack initiation.
• Weight Reduction – Plastic Molding: Blending ratios and process parameters (temperature, mixing) were shown to influence mechanical, thermal, optical, and morphological properties of PC/ABS and PLA parts.

Benefits and Practical Applications

Shimadzu’s integrated evaluation platform accelerates material selection, quality control, failure diagnosis, and process optimization. This supports the development of lighter, safer, more efficient CASE vehicles and components while meeting stringent environmental and regulatory requirements.

Future Trends and Opportunities

Advanced trends include AI-driven data analysis, in situ and operando characterization under real-world conditions, further miniaturization of sensors, higher-resolution CT and microscopy, integrated multi-physics simulation with live validation, expanded additive manufacturing monitoring, and life-cycle assessment for sustainable materials and recyclability.

Conclusion

Comprehensive, multifaceted evaluation strategies leveraging Shimadzu’s broad instrumentation portfolio are essential to address the diverse technical challenges of CASE mobility and weight reduction, paving the way for next-generation automotive innovations.