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Rallye meets mass production

The new hybrid material litecor® is light and easy to work with

The inspiration came from motorsport: Incorporated into the Polo R WRC made by Volkswagen you will find extensive development work – and the steel hybrid material litecor® made by the steel business of thyssenkrupp. For the road version of the Polo R WRC, engineers at both companies developed a front hood made of the innovative material. While the bodyshell comes from the mass-produced Polo, the engineers reinvented many other components such as the hood. The result: The front hood is almost 2 kg lighter than the engine hood used in series production. The material for 2,500 front hoods was produced for the special range at the pilot plant in Düsseldorf. Further advantages: Lightweight construction with litecor® is economically and ecologically sensible. Due to the weight reduction, resources can be saved during production and fuel during the use of the product. Moreover, the material can be readily shaped in the same way as monolithic steel sheet. Folding, beading and spot-welding in a modified process are possible.

A light but nevertheless stable sandwich

For the production of litecor®, the experts at the steel business of thyssenkrupp connect a light polymer core with good shear strength to two very thin steel cover plates to form a stable contact material. The modern sandwich material is ideal for the economic lightweight construction of two-dimensional auto body parts such as the roof, door, tailgate and hood. It is equally ideal for interior parts such as the vehicle floor: Because litecor® is significantly lighter than monolithic steel sheets and therefore represents an alternative to the use of aluminum – especially in the cost-sensitive high-volume markets.

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