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Innovation for the Automotive Industry

With our broad range of expertise, CSIRO is well positioned to work with you in developing the next generation of motor vehicles.
Collaborating for success
Partnering with CSIRO gives you access to thousands of scientists and engineers from Australias most trusted and respected science and technology research organisation. Innovation at the interface
CSIROs broad capability base and deep understanding of automotive industry applications are proven through significant industry outcomes. Some of our achievements include: electric traction motors integration of vehicle systems energy storage and management systems lead-acid and lithium battery technology superhard, corrosion-resistant low friction coatings hybrid drivetrains hydrogen liquefaction and refuelling supercapacitors powder coating of plastic components. > CSIRO is well positioned to work with you in developing hydrogen vehicle technology.

Strong science
Our core research includes: light metals cast materials mathematical modelling hybrid vehicle technology power and control electronics laser processing and joining vision systems manufacturing systems. With this range of expertise, CSIRO is well positioned to work with you in developing the next generation of motor vehicles. > CSIROs deep understanding of automotive industry applications is proven through our impact for industry.

Flexible partnering
CSIRO is a key member of the: Cooperative Research Centre for Cast Metals Manufacturing Victorian Centre for Advanced Materials Manufacturing Cooperative Research Centre for Automotive Technology Cooperative Research Centre for Advanced Manufacturing. We build short- and longterm partnerships around: collaborative research contract research commercial licensing arrangements. We also provide consulting and testing services.

CSIRO is addressing the important issues facing the automotive industry with active programs in environmental sustainability and new materials through to virtual design and manufacturing systems.
Our capabilities in action
CSIRO has decades of demonstrated expertise in automotive materials and manufacturing technology, from mathematical modelling and computer aided visualisations to welding and advanced composite materials. Casting technologies
T-Mag
T-Mag, an innovative magnesium casting technology, enables super-light magnesium alloys to be cast into high integrity, high strength automotive components which are cost-competitive with those made from aluminium or steel. T-Mag Pty Ltd, a joint venture between CSIRO and three Australian companies, is taking T-Mag technology to the global automotive industry.

Advanced materials
CSIRO has considerable expertise in textiles light metals sustainable manufacturing heat recovery visual inspection autonomous vehicles adaptive supply networks. Technology already used by automotive manufacturers and suppliers includes: advanced composite fabrication textiles and fibres polymer coatings bonding techniques. We also work with component suppliers. For example, we collaborated with a leading manufacturer to produce new high strength alloys for bearings. > CSIROs casting technology makes components made of super-light magnesium alloys an economically viable alternative.

Mathematical modelling
Our specialists in simulation, mathematical problem solving and information visualisation cover: finite-element modelling adaptive supply networks whole-of-life modelling human-vehicle interfaces planning and operations optimisation flexible virtual enterprises passenger cabins as smart spaces.

Advanced thixotropic metallurgy

CSIROs Advanced Thixotropic Metallurgy (ATM) heralds a new age of quality high pressure die casting. ATM is particularly suited to aluminium or magnesium alloys. It offers lower costs and improved quality in products such as safety critical automotive components.

Safety systems
CSIROs Safe-T-Cam system monitors heavy vehicle traffic on Australias highways. Our award-winning RoadCrack system is used to assess the integrity of the road surface from a vehicle travelling at normal highway speeds. > CSIRO has specialists in simulation, mathematical problem solving and information visualisation.

Our strengths include a team of internationally recognised experts and a longstanding reputation for excellence in technology and business innovation.
Meeting future challenges
Improving core technologies and tackling the big issues for a sustainable future. Lightweighting
We are leaders in using light metals such as aluminium, magnesium and titanium. Our recent breakthrough in heat treatment of aluminium alloys has the potential benefit of lower vehicle mass and higher crash safety. Other research is pioneering twin-roll cast and finished-rolled magnesium sheet.

Energy storage
CSIRO is a world leader in designing technologies to deliver safer, lighter, more powerful and longer lasting mobile energy storage devices.

Supercapacitors
Supercapacitors are electrochemical capacitors that offer very high capacitance in a small package. CSIROs supercapacitor stores a large amount of charge and release it very quickly. This makes them ideal for short term, high energy applications such as whan an electric car accelerates. > CSIROs UltraBattery and supercapacitors.

Rapid design
CSIROs virtual design and engineering technology can more than halve the time from concept car to production vehicle. It integrates the design, engineering and manufacturing processes and significantly reduces the need for prototyping. For example, our augmented reality tools such as haptics (the ability to touch in virtual reality) can be used to visualise assembly processes.

Fuelling future transport

We are exploring the feasibility of alternative road fuels and assessing possible biophysical, social and economic impacts of their production and adoption. This work covers: biofuels synthetic fuels (coal to liquid and gas to liquid conversion) hydrogen as a fuel source.

UltraBattery
CSIROs UltraBattery integrates a supercapacitor with a lead acid battery. In comparison with conventional hybrid electric vehicle systems, the UltraBattery: lasts four times longer produces 50 per cent more power is about 70 per cent cheaper.

Environmental sustainability
Drawing on our long-term capabilities monitoring air pollution, CSIRO performs well-to-wheel analysis of alternative fuels to examine their climate-friendly status. With the rise of electrified vehicles, CSIRO is developing cleaner methods of electricity generation and smart ways of integrating distributed sources of energy.

Lithium battery
Our breakthrough research on room temperature ionic liquids is spearheading our development of a rechargeable lithium metal battery that is: safe works over a wide temperature range delivers 25 per cent more energy than a contemporary lithium ion battery of the same size . > CSIRO develops sophistocated power and control electronics.

On the road
The development of alternative vehicle technology is driven by, among other things, rising fuel prices and the need to reduce greenhouse gas emissions. Concept vehicles
Together with our partners CSIRO has been involved in the planning, development and production of low fuel consumption, low emissions vehicles.

Duoleta
In late 2005, CSIRO was part of an AutoCRC conceptual development investigating the technical and commercial feasibility of producing in Australia an ultra lightweight vehicle with low fuel consumption and low emissions. The Duoleta concept drew on petrol engine technology, avoiding the high cost and complexity of hybrid powertrains. The study found such a car could be made with features such as: fuel consumption <4 L per 100 km 0 100 km/h less than 10 s crash performance equal to the best car of its size suitable for freeway and local road high manoeuvrability seating for 4 with 4 doors. The Duoleta was designed for: export ease of disassembly and high recyclability ultra-low drag coefficient (<0.25) ultra-low kerb weight (~700 kg). The Duoleta concept revealed unrivaled performance and fuel consumption and very low CO2 emissions. > The aXcessaustralia low emission vehicle.

aXcessaustralia
Also developed in 2000, the aXcessaustralia low emission vehicle was a low-cost petrol-=electric series hybrid concept vehicle. It used technology from CSIRO and more than 80 Australian component manufacturers. It could halve fuel bills and slash air pollution by up to 90 per cent and was acclaimed at motor shows around the world. > The ECOmmodore was one of the worlds first family-size parallel hybrid petrol-electric cars.

ECOmmodore
CSIROs collaboration with Holden began with the development and demonstration of the ECOmmodore in 2000. This was one of the worlds first familysize parallel hybrid petrol-electric cars. It performs like a conventional V6, but with half the fuel consumption. The ECOmmodore has a combination of first generation CSIRO supercapacitors and specially designed, valve regulated, high power lead-acid batteries. These are controlled by an electronic energy management system which controls the hybrid powertrain.

< This artists impression of the Duoleta shows that radical appearance is not required to achieve functional and environmentally friendly objectives.

For further information about partnering with us: Light Metals Flagship Mr Sam Tartaglia Phone: +61 3 9545 2964 Email: sam.tartaglia@csiro.au Web: www.csiro.au/lightmetals For further information about light alloys: CSIRO Materials Science and Engineering Mr Barrie Finnin Phone: +61 3 9545 2951 Email: barrie.finnin@csiro.au Web: www.csiro.au/cmse For further information about low emission transport: Energy Transformed Flagship Dr John Wright Phone: +61 2 4960 6080 Email: john.wright@csiro.au Web: www.csiro.au/et