NIST and the Automotive Industry

See related NIST projects on the NIST Electronics/Semiconductor industry sector information web page.

Automotive Materials

In the highly competitive automotive market, manufacturers must continually improve their products. And that means they need superior materials. NIST programs help improve many of the materials that go into cars from exterior paint to polymer body panels and alloy engine parts. Below are links to some of our materials research projects.

Materials Performance Group—focuses on mechanical properties, deformation processing and fracture, and the effects of corrosion on materials performance; provides industry with materials performance and corrosion control data, hardness standards, models for processing aluminum metal matrix composites, and standard test methods. Contact: Richard Fields, (301) 975-5712.

Metallurgical Processing Group—aids metals producers and manufacturers by developing measurement and control technologies which can be used to improve the reproducibility and efficiency of industrial processes, and the quality of the resulting materials. Contact: Stephen Ridder, (301) 975-6175.

Polymers Division—helping industry overcome problems in bringing light-weight, corrosion-resistant composites into commercial use by investigating cost-effective fabrication methods and identifying ways to predict long-term performance. Contact: Eric Amis, (301) 975-6681.

Ceramics WebBook—a resource for ceramic materials researchers and engineers; contains evaluated data on ceramics properties.

Ceramics Division—see the NIST Ceramics Division homepage for links to publications, programs, facilities, and events. Contact: Debra Kaiser, (301) 975-6119.

NIST Center for Neutron Research—probes automotive materials with state-of-the-art neutron research tools; contributes to improved measurement of residual stress in automotive components; measures structure to help improve processing of new lightweight composites and next generation batteries and fuel cells. Contact: Patrick Gallagher, (301) 975-6210.

The NIST Advanced Technology Program co-funds industrial research on high-risk, high-payoff ideas, including projects with potential to boost the competitiveness of the U.S. automotive industry. Contact: ATP or 1-800-ATP-FUND.

Manufacturing Composite Structures—a NIST Advanced Technology Program effort to assist U.S. companies develop the technical capability to produce affordable high-performance composites for large scale commercial applications including automotive parts. Contact: Felix Wu, (301) 975-4685.

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Mechanical and Dimensional Measurements

Making quality cars and car parts means sub-millimeter measurement precision on the assembly line. Through work with NIST, U.S. auto makers have greatly improved measurement accuracy in their complex manufacturing processes. That translates into fewer manufacturing errors and less shakes and rattles on the road. Here's how NIST helps.

NIST's Manufacturing Engineering Laboratory—works to improve the competitiveness of U.S. manufacturing by developing and applying measurement standards and technologies. Contact: melwebmaster or (301) 975-3400.

Engineering Metrology—develops the techniques and standards for length and geometric measurements needed to make sure parts conform to design specifications. Contact: Theodore Dorion, (301) 975-3468.

Large Scale Metrology—improves measurements on the scale of one meter or larger and helps reduce the problem of parts not meeting measurement tolerances. Contact: Steven Phillips, (301) 975-3468.

Measurement Services for Mechanical Quantities—provides U.S. industry with best-in-the-world-class measurement services for the mechanical quantities of mass, force, sound pressure, acceleration, shock, and ultrasonic power. Contact: David Evans, (301) 975-6637.

Manufacturing Processes

Today, the average new car has some 14,000 to 15,000 parts and accessories. Manufacturers' processes must flow together seamlessly in order to produce a quality car. NIST research is helping manufacturers improve their processes. Here's how.

Characterization and Performance Improvement of Machining Systems—develops machine tool performance evaluation standards so manufacturers can better assess which machine tool is best for the job. Contact: Johannes Soons, (301) 975-6474.

Predictive Process Engineering—develops measurements and standards for accurately predicting the outcome of parts production processes so that one day parts are made right the first time. Contact: Robert Ivester, (301) 975-8324.

Sensors, Interfaces and Networks for Metrology Manufacturing—accelerates the development of smart sensor technology and sensor networks by working on standard interfaces for connecting sensors to microprocessors. Contact: Kang Lee, (301) 975-6604.

Another NIST Advanced Technology Program project could develop and refine a revolutionary technique for making a wide range of hardened steel parts, slashing manufacturing costs by up to 30 percent and adding $6 billion to the U.S. economy every year. Read more.

Honeywell Technology Center of Minneapolis, received a NIST Advanced Technology Program award to develop and design an economical process to manufacture large complex metal parts through metal injection molding. Such a process has the potential to cut production costs for large complex metal parts, such as automotive transmission parts, by 50 percent. Read more.

The NIST Advanced Technology Program awarded $4.8 million to the Auto Body Consortium to improve the quality of vehicle assembly. The consortium developed the 2- millimeter assembly process, decreasing dimensional variation from 5 to 6 millimeters to 2 millimeters or less. Read more.

The NIST Advanced Technology Program awarded $3.5 million to the National Center for Manufacturing Sciences, Inc., of Ann Arbor, Mich., to improve machine tool spindles. One of the resulting spindle designs could save the auto industry 100,000 hours in annual machining time for a single part. Read more.

Motor Vehicle Manufacturing Technology—a NIST Advanced Technology Program effort to help U.S. companies develop motor vehicle manufacturing technologies to decrease changeover time for new models from 48 to 24 months.

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Systems Integration and Interoperability

In the information age, manufacturing relies on multiple, technically complex systems working well together within and between shops. Auto manufacturers are getting help from NIST in making sure a set of specs means exactly the same thing to different manufacturing systems. Read on to see how we're improving interoperability and integration.

Intelligent Open Architecture Control of Manufacturing Systems—develops measurements and standards to support robotic control technology for process and measuring equipment. Contact: Frederick Proctor, (301) 975-3425.

Manufacturing Enterprise Integration—demonstrate the potential for reducing the cost of Business-to-Business (B2B) software integration through new types of semantics-based measurements, standards, and infrastructural technologies that enable the building and testing of self-integratable applications. Contact: Al Jones, (301) 975-3554.

Product Engineering—develops information protocols for interoperability of computer-aided design and product engineering systems. Contact: Ram Sriram, (301) 975-3507.

Shop Floor as a National Measurement Institute—performs research that will help manufacturers demonstrate measurement ability traditionally performed only in a nation's primary measurement lab, but now required for global trade. Contact: Steven Phillips, (301) 975-3565.

Systems Integration for Manufacturing Applications—focuses on defining, testing, and promoting standards for interoperability solutions; facilitates remote access to scientific and engineering data; and researches collaborative manufacturing environments. Contact: Mark Carlisle, (301) 975-3982.

Intelligent Networked Simulation and Control—Real Time Innovations, Inc. received funding from the NIST Advanced Technology Program to develop a high-speed network to test integration of individual components from multiple remote locations.

Electronics

More than ever before, new cars are wired. Electronics under the hood control everything form engine performance to braking and traction. And electronic devices such as GPS locators, cellular phones, and flat panel video displays are proliferating in the passenger compartment. NIST research has supported the development of these devices, and NIST continues to help solve the challenges of operating delicate electronics next to hot engine parts.

Mathematical Modeling for IGBT Semiconductor Devices—develops mathematical models for insulated-gate bipolar transistor semiconductors used to design electronic ignition systems; develops model validation procedures and associated experimental techniques for IGBT and other semiconductor devices. Contact: Allen Hefner, (301) 975-2071.

Solders and Solderability Measurements for Microelectronics—develops test methods and guidelines for evaluating solder and solderability of components; assesses solderability and reliability of lead-free and fatigue-resistant solders designed for automotive use. Contact: Frank Gayle, (301) 975-6161.

Solder Properties Database—provides an online database of solder properties emphasizing new lead-free solders.

Flat Panel Display Metrology—investigating the best ways to measure characteristics of newly emerging flat panel displays for automotive, consumer, computer, and avionics use; helping develop national and international standards for flat panel display characterization. Contact: Edward Kelley, (301) 975-3842.

Office of Microelectronics Programs—Manages the National Semiconductor Metrology Program, a NIST-wide effort designed. Contact: nsmp@nist.gov or (301) 975-4400.

Semiconductor Electronics Division—performs research to provide necessary measurement tools, data, models, and standards to the U.S. semiconductor industry. Contact: Dave Seiler, (301) 975-2074.

See related NIST projects on the NIST Electronics/Semiconductor industry sector information web page.

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Safety

New cars equipped with air bags and anti-lock brakes are safer than ever before, but driving remains among the riskiest things Americans do. More than 40,000 Americans die in car crashes annually, and more than 3 million are injured, according to National Highway Traffic Safety Administration statistics. The links below describe programs that help the auto industry make safer cars.

Crash Avoidance Systems—developing and applying intelligent control technology for civilian and military vehicles; developing performance measures for first-generation crash avoidance systems. Contact: Maris Juberts, (301) 975-3424.

Improving Vehicle Fire Safety—See the results of a NIST and General Motors study on how flame retardant paints and caulks might better protect vehicle occupants in a post-crash fire. Contact: Anthony Hamins, (301) 975-6598.

Flammability of Minivan Parts—See the results of a study on flammability of minivan parts in order to obtain valuable data and insights on vehicle fires. Contact: Thomas Ohlemiller, (301) 975-6481.

Reducing Emissions

New car models are less polluting than ever before, and new technologies offer the hope of far less polluting vehicles in the not-too-distant future. NIST has helped car makers reduce and eliminate pollutants like lead, CFCs, and hydrocarbon emissions. Follow the links below to see how we're helping.

NIST Databases help assure accuracy with environmental measurements. Our Quantitative Infrared Database helps industry and environmental regulators measure air pollutants with great accuracy. Contact: Pamela Chu, (301) 975-3939.

Our REFPROP database helps automotive engineers design air conditioning systems that don't rely on ozone-depleting CFC compounds. Contact: Eric Lemmon, (303) 497-7939.

NIST Traceable Reference Materials—In order to better meet the growing demand for environmental emissions testing, NIST developed NTRMs, or NIST Traceable Reference Materials. Produced commercially with NIST guidance and monitoring, these gas standards enable accurate testing of industrial and automotive emissions. Contact: Frank Guenther, (301) 975-3939.

Here's a list of NIST Traceable Reference Material suppliers.

Physical and Chemical Data

The NIST Standard Reference Data Program serves science and industry with world-leading technical data services and products. This page provides links to scientific databases in several specialties. Contact: (301) 975-2008 or Contact SRD.

The NIST Chemistry WebBook provides users with easy access to chemical and physical property data through the internet. You can search by name, formula, author, or structure and retrieve phase, reaction, spectral, thermophysical, and many other properties.

Physical Reference Data—look up physical constants, atomic and molecular data, ionization, x-ray, and gamma ray data, nuclear physics data, and condensed matter physics data. This page also has links to other online NIST reference databases.

Chemical Kinetics Database—a compilation of kinetics data on gas-phase reactions; searchable by specific reactants, reactions resulting in specific products, all reactions of a particular species, or combinations of these. Available free online. Contact: Robert Huie, (301) 975-2559.

Computational Chemistry Comparison and Benchmark Database—this database contains computational thermochemical data for a selected set of about 600 gas-phase molecules and tools for comparing experimental and computational thermochemical properties in the database.

Small Manufacturers and Parts Suppliers

NIST's Manufacturing Extension Partnership , a nationwide network of assistance centers for smaller manufacturers in all 50 states, and Puerto Rico, offers experts to consult with small to mid-sized manufacturing firms. Assistance covers advice on ways to modernize, increase efficiency and take advantage of information technology. Automotive parts manufacturers and suppliers are among the more than 100,000 firms receiving assistance between 1988 and 2000. Contact: 1-800-MEP-4MFG.

For example, Solvay Automotive of Adrian, Mich., worked with two MEP centers, the Edison Industrial Systems Center and the Michigan Manufacturing Technology Center to solve problems in its manufacturing line. As a result, the company experienced a 25 percent increase in production.

Another automotive parts supplier, Mennie's Machine Company of Mark, Ill., needed QS 9000 Certification to meet the demands of its auto manufacturer customers. The company participated in the ISO/QS 9000 Preparation Network, set up by the Illinois Manufacturing Extension Center and earned its certification.

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Other Resources

NIST outreach programs work directly with business and industry to boost U.S. economic competitiveness. Many automotive companies and their suppliers have benefitted by taking advantage of these programs.

NIST's Advanced Technology Program spurs innovation in U.S. industry by co-funding high-risk, high-payoff projects with private industry. Contact: 1-800-ATP-FUND or atp@nist.gov.

Smaller manufacturers face many challenges in our technology-driven environment. To help meet these challenges, NIST started the Manufacturing Extension Partnership program in 1988. This nationwide network of centers, now in all 50 states, has assisted more than 100,000 U.S. firms, including automotive parts suppliers. Contact: 1-800-MEP-4MFG.

The Baldrige National Quality Program recognizes performance excellence and quality achievement by U.S. manufacturers, service companies, educational organizations, and health-care providers. Auto industry firms have been competing for the Baldrige Award since it was established in 1988. Five automotive suppliers and one manufacturer have been among the winners: