PROVE - Production Readiness Of Very light-weight Exhausts

Unipart Eberspächer Exhaust Systems (UEES), Aston Martin Lagonda Limited (AML), JSE Limited (JSE) and Coventry University (CU) recently completed a Niche Vehicle Networks CR&D project to create an ultra-light-weight exhaust by using hand welded thin-gauge material, reducing part count and exploring the boundaries of high grade stainless steel and manufacturing processes, while maintaining Aston Martin exhaust system deliverables. Overall, the system weight reduced by 45% from 27.8 kg to 15.1 kg, a saving normally associated with titanium. This project now seeks to develop the innovative manufacturing techniques which will be required to produce such systems on a commercial basis. In order to achieve this, innovation will be required in the fields of: tooling design and performance in relation to boost tube bending capability; jig design and manufacture to overcome the challenges of concentricity and co-axiality; and in robotic weld techniques to ensure consistent, repeatable performance. The project is scheduled to last for 9 months and conclude at the end of March 2016.