Fisker's First Hybrid Features Aluminum Frame

Aluminum will play an important role in lightening newelectric and hybrid cars.

Exhibit A is an advanced aluminum space frame in the FiskerKarma sports car that debuts tomorrow at the Geneva Motor Show in Switzerland.

Fisker Automotive's engineering team designed the Karma'sspace frame around the car's Q-DRIVE®series-hybrid powertrain, filing for multiple patents. Q-DRIVE® features a2.0L turbocharged ECOTEC® engine/generator set, a lithium-ion battery packfrom A123 Systems and a rear-mounted 403 hp traction motor assembly.

The Karma, whose prototype was first shown in January 2008at the North American International Auto Show, is expected to have a stickerprice of $87,900. The vehicles will have a range of about 50 mi as anelectric vehicle, and will only require one gas fill-up a year if operatedstrictly on the electric motor.

The space frame minimizes weight throughuse of 5000- and 6000-series aluminum alloys and a unique extrusion-intensivearchitecture. 5000 series are alloysmade with magnesium, and derive most of their strength from workhardening. 6000 series are alloyed withmagnesium and silicon, and are easy to machine.

"Our top priorities when we designed the Karma's aluminumspace frame were that it have extremely high torsional rigidity and could beeasily modified to accept Karma model variants," says Henrik Fisker, CEO, FiskerAutomotive. "We benchmarked some of the world's best cars to create anall-new space frame that will deliver an exhilarating experience behind thewheel."

Torque Tube

A super-structural tunnel running down the car's centerlineis the backbone of the vehicle. It not only houses the battery pack but acts asa torque tube connecting front and rear sections. For optimal strength theKarma's space frame is joined with 79 m of precision welds and 1,058self-piercing rivets.

Few cars match its statistics:

Static torsionalrigidity – the amount the space frame resists twisting forces when enteringa ramp at an angle, for example – measures more than 33,000 Newton-meters perdegree (Nm/deg).

Static bendingrigidity – the amount the space frame resists flexing forces as the carenters a ramp straight on, for example – measures more than 23,000 N/mm.

Dynamic stiffness– the space frame's resistance to resonant vibrations like those felt whendriving over a sharp bump or rough road surfaces – is also world class.

Front-impact protection starts with a patent-pending,multi-cell tempered aluminum crush box that displaces high-impact energy awayfrom passengers. Its design permits easy replacement, reducing repair coststhat could lower insurance premiums. Dual Phase 600-Series steel-reinforcedcomponents in the doors and "B" pillars provide side-impact protection.

And the lithium-ion battery's location in the center of thecar places it away from impact areas. The Karma can be fitted with a solar-paneledroof to aid in the recharging of its batteries and  also to help power the cabin climate controlsystem. The factory-fitted solar roof can generate up to a half kilowatt-hour aday, boosting range up to 4 to 5 mi when the sun is shining.

Valmet Automotive will assemble the space frames at a plantin Uusikaupunki, Finland that has been used to produce Porsches and Saabs.Fisker Automotive operates an R&D center in Pontiac, MI. "The Karma isscheduled to start arriving in showrooms late this year," says Russell Datz,director of public relations for Fisker. " We have a network of 45 U.S. retailersthat have existing showrooms and service centers."

Based in Irvine, CA, Fisker was created in 2007 to leveragethe design capabilities of Fisker Coachbuild, LLC, founded by auto design veteransHenrik Fisker and Bernhard Koehler, and the PHEV powertrain capabilities ofQuantum Fuel Systems Technologies Worldwide,a Tier 1 supplier of clean vehicle technologies. Previously, HenrikFisker was design director for Aston Martin and president and CEO of BMW'sDesignworksUSA. Koehler, whose title is chief operating officer, led operationsfor Ford's Global Advanced Design Studio and created concept cars for AstonMartin, MINI and BMW.

The first product of the collaboration is the four-door Karma, described as the world's first premiumplug-in hybrid electric vehicle (PHEV). The Karma will be followed by a secondline of lower cost, high volume automobiles by 2012.

According to data from the Aluminum Association of America: