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Material Properties
Sp.
Gravity
Density
kg/ cu.m.
Melting
Point
Mod. of
Elasticity
GPa
Torsional
modulus
GPa
Aluminium 2.69
2699
580-660
69
25
Mild Steel
7.85
8097
1900
207
84
Copper
8.93
9200
1083
120
45
Magnesiu
m
1.75
1803
565
44
17
Glass
2.64
2520
1500
69
--
ABS
1.05
1082
125
1.4-2.7
--
PVC
1.4
1442
95
2.8
--
Introduction I
The passenger car of today and, even more so, the car of the future
has to satisfy very high demands. Aside from being a high
performance vehicle, that ensures driving ease, safety and comfort,
it has to comply with strict and necessary environmental demands.
This environmental awareness and the laws endorsing it have
forced the automotive industry to focus on ways to reduce the
vehicle weight. Lighter cars invariably mean lower fuel consumption,
resulting in reduced exhaust CO2 emission, which is a major
atmospheric pollutant.
Incorporating aluminium in the car fulfils this requirement in an
exceptional manner. For example, compared to traditional steels,
aluminium rolled sheet for doors, hoods or wings can amount to a 50
% weight reduction. The tradition of using steel and the cost of
aluminium are challenges for the incorporation of aluminium into the
automotive sector.
Introduction II
Currently, new European cars contain on average 130 kg of
aluminium. This quantity varies significantly depending on the brand
and the class category.
Aluminium can be used for various car parts:
1000
2000
Copper
3000
Manganese
4000
Silicon
5000
Magnesium
6000
Magnesium + Silicon
7000
Zinc
8000
9000
Unallocated
Aluminium Alloys
Two distinct groups are those that can be
heat treated and those that can not be
heat treated.
Heat treatable series are 1000,3000,4000
and 5000.
Non-heat treatable series are 2000, 6000,
7000 and 8000.
Performance specialization
Material
Selection
Fabrication
Appearance
Mechanical Durability
Properties
Special
Requirements
Machining
Shape
Strength
Atmospheric
Electrical
conductivity
Forming
Surface
finish
Stiffness
Chemical
Unit weight
Joining
Hardness
Unit
Cost
Typical use of
aluminium alloys in a car body
Manufacturing Process
Welding needs more energy because
higher thermal conductivity.
Recent trend of using adhesives in place
of riveting has improved results.
Use of aluminium extrusions has
revolutionized fabrication of vehicle
bodies.
Steel Vs Aluminium
Following few slides present comparison
between steel and aluminium usage in
automotive sector.
Formability
Aluminum's Formability is approximately 2/3 that of
steel (less forming range). This is a very important
advantage for steel for vehicle styling and overall
manufacturing robustness.
Advantage: Steel
Hardness
Aluminum's hardness is lower than steel's. Stone
chips and surface quality are harder to maintain for an
aluminum body over a vehicle's lifecycle.
Advantage: Steel
Damping
Noise, Vibration, and Harshness (NVH). The ability of
any material to attenuate airborne noise is directly
proportional to its mass. Regarding airborne noise, steel
clearly has an advantage in most cases.
Advantage: Steel
Magnetic
Steel is magnetic, aluminum is not; very important in recycling
end of life vehicles. Steel is easily recycled because of its
magnetic properties versus other nonferrous materials such as lead,
copper, zinc, and aluminum. Thus, Steel separates extremely
efficiently, but the nonferous scrap will possess all the unwanted
residual materials as well (polymers, glass, adhesive, ceramics,
etc.).
Advantage: Steel
Galvanic potential
Aluminum's galvanic potential is high, while steel's is low. On
an auto body, when aluminum and steel are in direct contact,
accelerated corrosion is evident. There are barrier technologies
available to help with this condition when mixing metals, but at a
significant cost impact.
Advantage: Steel
Selection of Aluminium
Design engineer needs to optimize the use of
steel or aluminium alloys based
utility,
function,
ease of manufacture,
durability,
safety,
cost effective in manufacture and
reduced pollution for vehicle.