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LOW WEIGHT VEHICLE PROPERTIES OF ALUMINIUM ALLOYS FOR BODY STRUCTURES

Objective


Knowledge of aluminium alloys is recent and limited in comparison with steel know-how. Collection of existing data has identified actual possibilities and has selected appropriate alloys for sheet materials, cast parts and extruded profiles. Evaluation of physical and mechanical characteristics of the aluminium alloys with indication of their mechanical and thermal properties have given the engineering choices. A review of shaping processes such as deep drawing, bake hardening, casting, bending, welding, have determined better metallurgical capabilities and define the precise process conditions to be chosen. Representative specimens have been tested in simulated conditions for stiffness, fatigue, impact... for estimation of the service life behaviour of assembled structural parts. Conventional procedure tests have been performed on several high strength aluminium alloys after simulative process conditions in order to determine the levels of mechanical properties such as tensile, stiffness, impact and fatigue strength. These determinations allowed to quantify the possibility of weight reduction such as 40% using 120Mpa fatigue strength aluminium alloys (A 356 for instance) for body panels. This precompetitive work has established a guideline in the choice of materials and specification for design of vehicle and has supplied data information in forming processes for manufacturing of vehicle.
The use of aluminium alloys for vehicle body structures can result in a 40% weight saving but there are some technical barriers for their application in mass production. This project will select high strength aluminium alloys for their general behaviour in service life.Characteristics of aluminium alloys products as sheet materials, cast parts and extruded profiles will be determined for optimized design of body structure with mechanical properties testing such as tensile strength, ductility, impact strength, stiffness and fatigue resistance. Metallurgical compatibility of aluminium alloys in such shaping processes as drawing, bending, casting, heat treatment, assembling, paint baling,... will be evaluated for optimization of manufacturing processes.

Funding Scheme

CSC - Cost-sharing contracts

Coordinator

RENAULT
Address
9/11 Avenue Du 18 Juin 1940
92500 Rueil-malmaison
France

Participants (14)

AB VOLVO
Sweden
Address
Dept 06430 Bc1
40508 Gothenburg
ALUSUISSE LTD
Switzerland
Address
Bad. Bahnhofstr. 16
3965 Chippis
AMAG-FORSCHUNGS & ENTWICKLUNGES GMBH
Austria
Address

5282 Ranshofen
Alcan International Ltd
United Kingdom
Address
Southam Road
OX16 7SA Banbury
Alures ScpA
Italy
Address
Via G. Bovio 6
28100 Novara
Bayerische Motoren Werke AG (BMW)
Germany
Address

80702 München
Centro Ricerche Fiat ScpA
Italy
Address
Strada Torino 50
10043 Orbassano
DAIMLER-BENZ AG
Germany
Address

8000 München
HYDRO ALU
Norway
Address

4265 Haavik
Pechiney
France
Address
Centre De Recherches De Voreppe Zone Industrielle
38340 Voreppe
Peugeot SA
France
Address
Route De Gisy
78140 Vélizy-villacoublay
ROVER GROUP PLC
United Kingdom
Address
Banbury Road Lightorne Gtc
CV35 0BL Warwick
SWEDISH INST FOR METALS RESEARCH
Sweden
Address
Drottning Kristinas Vag 48
11428 Stockholm
THE WELDING INSTITUTE
United Kingdom
Address
Granta Park, Great Abington
CB1 6AL Cambridge