Products + Processes

Excerpt

The body of the new Porsche 911 is 7 % lighter than its predecessor. This is thanks to a further refined hybrid design using aluminum, steel, and composite materials. Despite the drop in weight, there is no loss of stability, rigidity and safety, which have even been strengthened in some areas compared to before. The company is using hybrid construction for an A-pillar for the very first time. The reinforcement with organic sheet, injection- molded ribs, and structural foam replaces the previous reinforcement using high- tensile steel tubing. The A-pillar itself comprises higher- and maximum-strength sheet metal components made from e.g. boron steel. Except for the front apron and rear trim, the car's outer shell is all-aluminum. The sidewall of the coupé alone reduces the overall weight by around 12 kg. Besides high- tensile steel, greater use has been made of extruded aluminum profiles for the body shell, for example in the front and rear side members, inner and outer rocker panels and floor pan reinforcers. For the new 911, Porsche is also making increased use of die-cast aluminum components, for example in the front shock absorber mountings, rear tunnel casing and rear side members. One of the new joining techniques the company is using is friction welding with countersunk bolt heads to join together aluminum and steel.

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