Focus on Aluminum Fabrication & Solution Providing
aluminum advances: aluminum passes iron among automotive materials in use worldwide; what lies ahead?
According to the duckerworld report released on 2006,-
Aluminum content of Light non
Commercial vehicles to be assembled in North America, Japan and the EU in 2006--
The average aluminum content of the global car reached nearly 280 pounds in the 2006 model year.
The report brought more good news about the rise in aluminum in the North American auto market, which averaged 319 pounds, up nearly 24% in the past five years.
In the historical context, the achievements made by aluminum in the first five years of the new millennium are only a continuation of the trend since the medium term1970s--
In the past 30 years, the aluminum usage of light vehicles in North America has increased every year.
Factors driving the increase in usage include continuous oil shocks, legislation encouraging automakers to improve fuel efficiency in their cars, and consumers\' desire for larger cars with more power, expanded functionality, and improved performance.
What are the factors driving material selection forward?
How can the aluminum industry help automakers cope with future challenges?
What are the new automotive aluminum technologies coming out soon?
These questions are discussed in this story. FOCUS ON R&D.
Six weeks after the Ducker report was released at the aluminum Society Spring meeting,
Gerald Cole, president of lightweight Strategy LLC, talked about opportunities for automotive aluminum.
Lightweight materials like aluminum, hersard, now in a number of factors, including rising gasoline prices, help the car makers in a unique position, Americans want to be independent from foreign oil, and worry about the contribution of car emissions to global warming.
Cole, a former senior technical expert at Ford Motor.
Ford said consumers are expected to continue
Sizepickup trucks and SUVs as well as cross vehicles and more fuel
Efficient Car (
Seven months before 2006, the United StatesS.
Passenger car sales growth 2.
2%, light though-
10 trucks are sold. 6 percent).
Ford and GM both make significant investments in hybrid and flex, he added
\"Is the aluminum industry involved in this technological change? \" Cole asked.
\"Developing low cost requires more and smarter R & D.
Lightweight aluminum automotive materials with cost and functionality help maintain the development of the US automotive industry. S.
At the forefront of the automotive industry, \"Cole said.
As an example, he cited the potential of continuous casting to help aluminum automotive plate products become more competitive on a cost-based basis in body applications.
\"In order to make continuous casting aluminum a viable process for stamping automotive sheets, a lot of research and development is required,\" says Colesaid . \".
The Ducker report agreed to use aluminum in \"new innovative applications ---
It is defined as all the components except the powertrain, the powertrain, the wheel and the heat exchanger ---
In light vehicles, North America is behind Europe and Japan is third.
In the field of aluminum closed board shipments, consumption in Europe will exceed the sum of North America and Japan in 2006, and the Ducker project will continue to do so at the end of the decade. Two-
In 2006, 30 of the world\'s 0. 57 billion-pound aluminum sheets (
Twice the shipment in 2002)
European automakers including BMW and Mercedes-
Produce more than one part of aluminum body structure every year-
Audi, Jaguar, Ferrari, Rolls-Royce and Lotus have almost reached their combined product. Aluminum body.
Similarly, according to Ducker\'s report, Europe is the largest aluminum user in the \"distant\"--
The aluminum consumption of these parts is more than double that of North America and Japan.
Taxiing or driving forward?
Despite Europe\'s leading position in innovative aluminum applications, 2006-
North American models still surpass European peers in the use of aluminum, with an average aluminum usage of almost 60 lbs per vehicle.
This is the result of North America\'s preference for larger, more aluminum
Engine strength and (larger)
Automatic transmission is in use, while diesel engines are more common in Europe.
Ducker further reported that although the light aluminum cylinder head conversion worldwideCar engine--
Traditional drivers of growth in aluminum usage--
Almost finished, the use of aluminum in the engine block still has considerable potential.
For the first time in 2006, most of North America\'s engines-52percent--were aluminum.
Ducker predicts that the continuous conversion from iron to aluminum will be the main driving force for the growth of aluminum usage in the United States and around the world.
If the use of steel in cars is decreasing, then steel has become a major obstacle to aluminum.
Nevertheless, the United StatesS.
The aluminum industry is working with government researchers to develop costs-
Effective aluminum solutions in innovative applications to improve fuel efficiency and help develop more eco-friendly light vehicles.
Alcoa cooperates with the Pacific Northwest (PNNL)
Daimler Chrysler and the technology department of heavy vehicles have completed a project that includes the development of three prototypes of light vehicle frames.
In 2006, a prototype of an aluminum-steel hybrid was tested on the chassis of a2003 Dodge Durango.
\"The test results exceeded everyone\'s expectations and succeeded until we launched a more challenging follow-up --
\"The Up program is called the next generation framework,\" said Mark Smith, head of the PNNL energy materials group.
The next-generation frame prototype gave up the steel part of the frame and completely focused on aluminum.
PNNL reports that the weight of the aluminum frame is saved by more than 40%.
Then tested the aluminum frame on the latest model of Dodge Durango. FUTURE NOW.
Initiatives such as the next generation framework are significant.
Block engine continues to conquer the world of cars, a paradigm shift brought about by another oil shock or fuel progress
Battery technology may limit the revenue of aluminum in the North American engine market.
Perhaps the future of cars brought about by this paradigm shift looks more like a recent Tesla Roadster.
Ar ar\'s \"engine\" consists of the largest and most advanced lithium-
Built-in ion battery pack-
San Carlos, California-
Tesla Motors said it was able to power cars from zero to 60 mph in four seconds.
A Ferrari electric car.
Part of the secret of the world.
Its aluminum chassis features first-class performance-
Built by Hydro Aluminum, based on the chassis used in theLotus Elise.
The bonded extruded aluminum chassis/tub keeps the Tesla sports car at a height of 2,400 pounds.
Aluminum is also used to help keep the motor running fast and cool.
Its aluminum case with air
It can work continuously at 250 degrees F so that it can operate at peak power.
Best sellers in the United States have become better.
At the same time, the Toyota subsidiary, Bodi aluminum, is trying to improve the productold gasoline-Poweredinternal-
Internal combustion engine.
The company makes aluminum engine blocks and cylinder heads for Toyota\'s top
While selling Camry and other models, it has also created a range of new technologies and costs.
Cutting Measures for model year 2007.
In April 2006, according to the Bloomberg market Problem Report, Bodinehas cut down the power plant of production cost to 2007 Camry byalmost 50% in the past three years, the scale is smaller, less
Expensive molds for the production of engine components.
Redesign of the previous model 3. 3-
55 pounds liter engine jam--
From its quality, while its capacity is increased to 3.
5 liters, car acceleration 40%.
The new cylinder head design contains fewer ports through which air and fuel travel requires fewer cores in the mold.
The ability of Bodine to install 12-part is the result of this redesign
A pedal machine instead of the old 30foot machines.
Foot Casters used to make Camry engine blocks have been replaced by smaller, more efficient casting machines.
The new casters use up to 40% lesspressure to inject aluminum into the mold, eventually creating stronger blocks with fewer bubbles.
Reduced injection speed means Toyota can make V-
6 The engine block adopts a mold of 5 tons instead of 29 tons, and the pressure is reduced by 35%. SAFETY FIRST.
When the latest
Jaguar XJ was launched six years ago, which is a revelation.
Aluminum car technology with Alcan-
Connection system capable of producing balance sheet-
The structure based on aluminum is similar to the traditional stamping structure, but lighter and harder-
Volume 1 of the world-
The aluminum masts produced set new standards for fuel efficiency, control and safety.
Nonetheless, the XJ is basically an aluminum version of a steel car.
New Jaguar XK (
Engineering part Novelis, supplier of rolledproducts)
Use more casting and profiles than theXJ-
Eliminating the need for many joints used to hold the stamping parts together.
Results: this is a harder and stronger body for better handling and safety.
Additional security features installed in XK convertible isstate-of-the-
Art flip protection.
The system consists of two aluminum arches hidden behind the rear passenger seat. A solid-
The Stategyro sensor system monitors the vehicle, and if it senses the beginning of arollover, deploys the arch to the height above the head of the passenger behind it.
At the front end of the XK, the windshield pillar--the\"A-posts\"--
Supported on the dashboard with strong aluminum castings and thick-
Center Wall aluminum extrusion.
There is an iron ring at the back and a reinforced windshield structure at the front, creating a rollover \"Cage\" on the passenger compartment to help protect the head of passengers wearing seat belts.
Designers not only pay attention to the safety of people inside the car, but also pay attention to the safety of outdoor personnel.
In the case of apedestrian impact, the unfolded aluminum cover on the XK automaticallops rose a few inches to create a buffer effect between the engine and the hood.
This deployment takes place in less than a tenth of a blink of an eye. -
Helps to isolate pedestrians from hard points in the engine compartment.
The advanced sensing system installed on the front bumper helps distinguish between pedestrian collisions and other possible front collisionsendcollisions.
Continued attention to energy supply and the environment indicates that the light weighing strategy remains important for the foreseeable future.
But aluminum must be high
The share of steel, magnesium and plastics in this market.
Automotive aluminum research and development must continue to seek to develop innovative new solutions in all areas of automotive-
Engine, transmission, chassis, suspension, closure, body structure, etc. --
Because its gains in one area may be offset to some extent by losses in other areas.
Changes in consumer preferences may also present challenges and opportunities (
For smaller vehicles, for example)
Even a large-scale \"paradigm shift \"(a large-
For example, the expansion of diesel engines in North America, or the widespread use of fuel
The Ducker report predicts that the global use of aluminum in cars will continue to grow, an increase of about 3% to three.
For the rest of the decade, 5% pounds a year.
Since then, the growth of aluminum is likely to depend on the technology being developed today.
This article first appeared in aluminum society magazine \"aluminum Now (www. aluminum. org)
Permission has been reproduced with the letter.
Authors can contact at j Simpson @ aluminum. org.