Thursday, September 07, 2006

More trucks, applications needed to balance tube

Applications for components made from steel tubing in North American-built family vehicles have increased significantly in recent years, and no one in the auto industry expects that trend to stop in the foreseeable future. However, one of the biggest reasons for using more steel tubing--i.e., weight-reduction also is expected to spur the development of smaller vehicles, which could limit the size of a lot of new tubular parts. In years in which the market for new cars and light-duty trucks is flat or slumping, the overall use of tubular steel in auto components could very well decline.

The automakers use steel tubing made from hot-rolled sheet, primarily in frame or structural applications, including hydroformed rails and crossmembers, in some of their vehicles. Those currently are among the fastest-growing applications. However, steel tubing also is growing in use in such parts as engine cradles, radiator supports, instrument panel (IP) support beams, and suspension system control arms. In most of those applications, too, the parts are hydro-formed. Tubular steel additionally lends itself well to many other parts, including body side pillars, roof rails and safety cage components.

Of course, tubing has been used for a long time in driveshaft and axle assemblies, exhaust manifolds, downpipes, intermediate pipes, mufflers and tailpipes. Nearly all of the exhaust system parts are made of stainless steel, however.

In subcompact, compact and intermediate-size vehicles, most of the tubular components are, of course, smaller than their counterparts in standard-size cars and trucks. Right now, most of the smaller vehicles being developed by the automakers are vehicles in the truck class, particularly sports utility vehicles (SUVs) and crossover vehicles that resemble SUVs or are part SUV, such as SUV pickups.

Virtually every automaker, including the transplants, will be coming out with new SUVs over the next few years that, as designed, are small and light enough to help the companies improve the average fuel economy of their trucks. Most of the new entries will be in the subcompact, compact and intermediate size ranges. If a given automaker can lure customers of its biggest trucks to a new intermediate, let's say, that will have the effect of improving his truck fleet fuel economy averages. Or, if he can lure customers of his intermediates to smaller units, it will have that same effect.

The auto companies think that can be done, depending on how well consumers like the styling and performance of the new models. For buyers of the SUVs and crossover vehicles, the biggest benefit of downsizing probably will be the promise of fuel savings, which, because of the higher prices at the pumps, should prove to be an attraction.

Another benefit of the downsizing, probably, will be the effect on the environment. Lighter-weight vehicles equipped with smaller, more fuel-efficient powertrains generally tend to have lower emissions.

The automakers' new focus on smaller vehicles began to take shape last year, with the introduction of the Ford Escape, Mazda Tribute, Chrysler PT Cruiser, and Pontiac Aztek models. Built off various car and minivan platforms, these are all small SUV-type crossover vehicles that are expected as a group to take more sales away from bigger SUVs than from cars.

Another sizable contingent of new vehicles is due out this year. Entering the market as 2002 models, these units include the Jeep Liberty, a 4-door SUV smaller than the 4-door Cherokee that it will be replacing; Saturn Corp.'s first SUV, a small unit dubbed the VUE; a "CS" sport wagon from Chrysler built off the company's mini-van platform; and the Buick Rendezvous, a "sport activity vehicle"" and a sibling of the Aztek.

After 2002, the new entries will include the Hummer H2 from GM, which, as designed, can be described as a scaled-down version of the massive, military-like Hummer H1, the industry's biggest multi-terrain sports vehicle; a small Lincoln SUV based on the Ford Explorer, the first compact-size SUV in Lincoln's lineup; and an entry-level compact-size SUV called the Pontiac Vibe that New United Motor Mfg. Inc. (NUMMI), Fremont, Calif., will build for GM. Actually a crossover vehicle, this small SUV will be built off the Toyota Corolla platform. NUMMI is a joint venture between GM and Toyota.

In addition, Toyota will start building a vehicle in Canada that will be similar in size to the Pontiac Vibe, and that also can be classified as a small SUV; Mitsubishi Motor Manufacturing of America Inc. (MMMA) will go into the production of its first-ever sport utility vehicle--a new Montero Sport--in Normal, Ill; and GM will start building an SUV for Cadillac that will be smaller than the Escalade. Using GM's new Sigma platform, this vebicle will look sometbing like the Cadilla Vizon concept model that's being put on display on the auto show circuit this year.

Also, in 2003 to 2004, Ford will introduce both an SUV and an SUV pickup based on the next generation compactsize Ranger pickup truck. A Chevy sport wagon built off GM's new Epsilon compact car platform is scheduled to enter the market in 2004, as is a tall car SUV similar to the Chevrolet Traverse concept vehicle introduced on the 2000 auto show circuit in the United States. The Traverse-like vehicle will be built by CAMI Automotive Inc., Ingersoll, Ontario, a joint venture between GM and Suzuki.


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