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[China Aluminum Industry Network] With the rapid development of automotive technology, automobile manufacturers have conducted a lot of research on the structural design, manufacturing technology, and material selection of automobiles, hoping to develop safe, reliable, energy-saving and environmentally-friendly new automobiles. Under normal circumstances, the body's own weight will consume about 70% of the fuel, so the most important issue to reduce the car's fuel consumption is how to make the car lightweight. Lightening the weight of automobiles firstly reduces the weight of the vehicle body, increases the quality of equipment, and reduces the engine load. At the same time, it can significantly reduce the resultant force on the chassis components, making the vehicle more maneuverable and economical. . The aluminum metal known as “light metal†has become lighter due to its light weight, wear resistance, corrosion resistance, good elasticity, high stiffness and specific strength, excellent impact resistance, good processing and reproducibility. Quantified preferred material. Aluminum alloy body vehicles are also favored for their advantages such as low energy consumption, safety and comfort, and relative load capacity.
First, the structural characteristics of aluminum body The use of aluminum metal in the car presents a trend of increasing year by year. There are many models that use aluminum partially or entirely, such as BMW, Audi, Volvo, Land Rover, and Jaguar. The aluminum used in the car body is basically aluminum alloy, which achieves the desired performance by increasing or decreasing the proportion of alloying elements and adopting an appropriate heat treatment process. At present, aluminum alloys used for automotive body panels mainly include Al-Cu (2000 series), Al-Mg (5000 series) and Al-Mg-Si (6000 series). Due to its good plasticity and high strength, the 6000 series aluminum alloy has become a preferred new body material for many automobile manufacturers. For different parts of the car body and different components, the alloy composition, type, and heat treatment process of the aluminum material used are also different. If the vehicle's bumper frame, reinforcement beam and side impact beam, etc., the aluminum used should have sufficient lightness and toughness, in the event of a collision should have good energy absorption characteristics. The use of aluminum components in the vehicle driveline not only has sufficient strength and toughness, but also has good thermal conductivity. Facts have proved that the use of aluminum in automobiles has indeed achieved good social and economic benefits.
When aluminum is used in all bodywork, according to the requirements of their functions in the body, they can be divided into castings, stampings, and die castings. Aluminum castings are manufactured to be able to carry large loads of components, significantly reducing weight but also Has high strength. These plates have complex geometries, usually vacuum-casted, giving them high strength. At the same time, they also have good ductility, good welding performance and high plasticity, ensuring that they have a high degree of safety in the event of a collision.
Of course, there are some deficiencies in the use of aluminum in automobiles. In the production of aluminum body cars, the welding of aluminum bodies consumes 60% more energy than welding traditional steel bodies, and in the event of a traffic accident, the maintenance cost of the aluminum body is higher. Due to the low melting point and poor repairability of aluminum materials, service technicians need to use special aluminum body repair tools and special process methods to repair.
Second, the aluminum body maintenance hardware requirements 1, aluminum body special gas shielded welding machine and profile repair machine Because of the low melting point of aluminum, easy deformation, welding requires low current, so must use a dedicated aluminum body gas shielded welding machine. The prosthetic machine cannot be click-stretched like an ordinary prosthetic machine. Only the special aluminum auto-body prosthetic machine can be used to weld meson nails and use a meso-stretcher to stretch.
2. The difference between the special aluminum auto body repair tools and the powerful rivet guns and the traditional accident vehicle maintenance is that most of the repaired aluminum bodies use riveted repair methods, which requires a powerful rivet gun. Moreover, the tools for repairing aluminum bodies must be dedicated and cannot be mixed with tools for repairing steel bodies. Because after repairing the steel body, there will be iron scraps on the tool. If it is used to repair the aluminum body, iron scrap will be embedded in the aluminum surface and cause corrosion to the aluminum.
3, explosion-proof dust collection and dust collection system in the process of grinding aluminum body, will produce a lot of aluminum powder, aluminum powder is not only harmful to humans, but also flammable and explosive, so there must be anti-explosive dust collection and dust collection system to absorb aluminum powder.
4. Independent maintenance space Due to the strict requirements of the aluminum body repair process, to ensure the quality of vehicle maintenance and maintenance operation safety, to avoid aluminum powder pollution and explosion on the workshop, a separate aluminum body maintenance station shall be established. In addition, the aluminum body maintenance personnel should carry out professional training, master the maintenance of aluminum body repair process, how to locate the tensile, welding, riveting, bonding and so on.
Third, the maintenance of the operation of the Notes 1, aluminum alloy sheet local tensile is not good, prone to cracks. If the engine hood inner plate is relatively complex, the high-strength aluminum alloy is used to improve its tensile deformation performance during the manufacture of the vehicle body, and the elongation rate has exceeded 30%. Therefore, it is necessary to ensure that the shape is not abruptly changed in order to avoid the occurrence of maintenance. crack.
2, the dimensional accuracy is not easy to grasp, rebound is difficult to control. In the maintenance, the method of releasing the stress by heating at a low temperature should be adopted as far as possible so that it will not be subject to secondary deformation such as rebound.
3ã€Because aluminum is softer than steel, defects such as bumps, scratches, etc. may be generated on the surface of the parts due to collisions during maintenance, dust adhesion, etc., so the cleaning of molds, the cleaning of equipment, the dust and air of the environment must be performed. Pollution and other aspects to take appropriate measures to ensure that the parts are in good condition.