Lightweight design approaches: 1. Material selection; 2. structural optimization; 3. Joining and system integration. SS, Al, Mg, and Ti alloys have been compared based on an ideal geometry (cylindrical rod): 1. SS is the heaviest but cheapest among the four metals to meet the same NVH (#1 natural frequency) and durability (stress) performances. A new flexible hanger design (two brackets + a rod) has been developed to replace the original 3-rod design: 1. Robustness in manufacturability; 2. Weight reduction.
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