New Course Development and Assessment Tools in Automotive Lightweighting Technologies

Automotive industry traditionally has reduced weight primarily by downsizing. Today, the strategy of downsizing vehicle has reached its limits. The OEMs are also facing substantial increases in Corporate Average Fuel Economy (CAFE) regulations in the U.S. and the other global markets. In this context, engineering students need to understand the underlying contributors that significantly play a role in vehicle Lightweighting. One of the main contributors is the appropriate use of a variety of high strength and lightweight materials to meet the mass (weight) targets. Another aspect and a more challenging issue is that a realization of how OEMs are learning to cost effectively join (weld, rivet, form and cast) lightweight (and often multi) materials on a global platform. How to impart these ideas in to a single course? The purpose of this paper is to discuss the need and strategic development of undergraduate and graduate level course materials on this topic and the best assessment techniques to gauge the understanding of the topics by the students. The teaching and learning experiences of the author in delivering this course and related topics to two different levels of student audience, and to general technical audience at invited talks and conferences are also briefly discussed in this paper. Finally, at appropriate time, all course material taught will be consolidated for possible publication as an introductory textbook on this subject matter