TECHNOLOGY

The Path To Lightweighting Is Paved By Innovation


For every 10 percent reduction in vehicle weight, there could be a 4.5 percent increase in fuel economy. That means every gram counts for GM scientists and engineers, who are driving the material innovations that pave the way for a better future.

In the all-new 2020 Chevrolet Corvette Stingray, two tiny – but mighty – engine mount brackets securely hold the 6.2L V-8 engine in place when it delivers 495 horsepower and 470 lb-ft of torque. These brackets are capable of supporting 20,000 times their own weight; combined, they weigh less than 1.5 pounds.

The brackets on the current generation of Corvette underwent a 40 percent mass reduction, a significant vehicle lightweighting achievement, thanks to a high-performance aluminum alloy material called HuCrAlloy.

Named after its inventor, Bin Hu from the GM China Science Lab, this new alloy mix contains chromium and disrupts a dominant, century-old recipe for die cast aluminum. The idea for the new mix emerged during one of Hu’s “aha” moments, when he was trying to improve the ductility and strength of an aluminum alloy.

The HuCrAlloy material’s potential was quickly identified by GM’s virtual engineering team based upon a computer simulation of its performance. The material made its debut in the engine mount brackets of the 2019 Cadillac V-Sport.

The Corvette engine mount is made of HuCrAlloy.

The Corvette engine mount is made of HuCrAlloy.

Vehicle lightweighting is an open innovation

Hu has been with the company since his Ph.D. internship almost a decade ago and materials innovation has always been an arduous – but fulfilling – journey for him. This breakthrough has been an exciting milestone for Hu and his colleagues.

“From concept to prototype, and finally to product, we innovated through teamwork and partnerships, so a new recipe could be brought to scale,” said Hu. “Open innovation matters as much as materials to the future of lightweighting.”

In the future, HuCrAlloy could be a solution for other components that feature complex design and demand high strength as well as structural integrity, such as the seat skeleton and wheel hub.