Chrysler 2011 Annual Report Download - page 56

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techniques developed by CRF, a reduction in drag coefficient of more than 3% was achieved without the use of aerodynamic spoilers
on the front wheel housing. That benefit will be even further enhanced once the rear profile of the vehicle has been optimized to take
account of the faster flow generated by the modification to the front wheel housing.
Biomethane. CRF assisted Fiat Group Automobiles in development of the biomethane supply chain in Italy through a detailed
analysis of applicable best practice in Europe. During 2011, CRF worked with local stakeholders in the Province of Trento (Italy) to
study the feasibility of constructing plants for the production of biomethane from various types of biomass. Specifically, a feasibility
and conceptual design study was completed for a biogas production and biomethane purification plant for the Oil Free Zone initiative
in Primiero and Vanoi (in the north-east of the Province of Trento). CRF is also a partner in the European “BIOMASTER” project,
whose objective is to demonstrate that biomethane can be a viable option for transport, despite regulatory and tax barriers currently
hindering deployment.
Weight reducing materials. In 2011, CRF introduced austenitic steel, an innovative material whose first application was the
crossbeam for the crash-box of the new Fiat Panda. The manganese-based austenitic steel used is the most resistant and flexible
cold pressed steel currently available. The innovation consisted of applying the metallurgical properties of traditional stainless
austenitic steel – high strength, excellent malleability, and good corrosion resistance – to automobile components at a lower cost
through the use of manganese, instead of the more precious and expensive nickel and chromium. The result was a weight reduction
of around 1 kg and cost reduction compared to the same component mounted on the Fiat 500, while also eliminating a step in the
pressing process. The resulting component represents a world first for application of this material on a passenger car.
Ecological materials. A concrete example of the application of eco-compatible materials is the use of the polyamide PA1010 (Zytel
FE240017) for fuel lines on diesel engines. The material was developed in collaboration with various suppliers and in 2011 it was
used for the first time ever on a large scale. Derived completely from castor oil, it represents a bio-alternative to PA 12 polyamides
and has several attractive properties including superior temperature resistance and long-term aging performance with biodiesels
when compared to PA 12. Use of PA 1010 also reduces dependence on PA 12, which is increasingly costly and difficult to procure
as a result of demand for the base material, butadiene, for use in higher margin production processes. The PA 1010 fuel line won the
top prize in the Environmental category of the Society of Plastics Engineers’ “Most Innovative Use of Plastics Awards”.
Vehicle life cycle and end-of-life. CRF has been using Life Cycle Assessment (LCA) for a number of years to assess environmental
performance of its European projects and also to assist Fiat Group Automobiles in design choices that impact the eco-sustainability
of products or processes. In 2011, LCAs were conducted for the NANOTOUGH, ATLANTIS and RIGENERA projects, as well as new
products for cathodic electropainting and biocomposites.
Report on Operations
“17,000
people
involved
in R&D
activities at
77 centers”