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[Aluminum Road Network] Introduction: Aluminum alloy material performance in the performance level is far better than steel, under the same conditions, all aluminum body can bring safety, control, fuel (power consumption) economy, durability and other comprehensive The problem with the upgrade is that the cost is still high, so non-luxury cars rarely use aluminum bodies. The Ford f-150 used the all-aluminum body as an advancement for civilians, but it was the American civilian car, and it was still a luxury car in China. When it comes to the aluminum body of a car, the feature that cannot be bypassed is light. Except those expensive running cars that will use carbon fiber in large quantities, lightweight design of automobiles is mostly achieved by using aluminum alloy in a large proportion. But apart from being light, what features of the all-aluminum body are worth examining? Maybe we start from the basic material level, and let's take a good look at this topic:
What is a full aluminum body? Is it really 100% aluminum?
Should there be no understanding of aluminum as pure aluminum? In fact, the concept of aluminum body, refers to the body structure is mainly made of aluminum alloy, not only allows the existence of some non-aluminum parts, and aluminum is also here in the form of alloy.
Aluminum alloys do not refer to an alloy. In fact, there are many categories. The internationally accepted rule is to use a four-digit plus a letter-headed state code to distinguish the types of aluminum alloys, such as the common 6063-t5 in the construction industry. The first digit is 1 for pure aluminum with purity greater than 99%, 2-8 for aluminum and copper, manganese, silicon, magnesium, magnesium + silicon, zinc, and other elements. 9 is the standby group. . The following figures are mainly used to distinguish, and the specific logic will not be described any more. In short, each formula of aluminum alloy has a unique label, corresponding to its unique characteristics. At present, the automotive aluminum body is mainly used in the 5 series and the 6 series, all belong to the material with low density, good tensile strength and fatigue resistance, and can achieve higher strength at much lower weight than the steel, including Audi. Asf aluminum body is widely used. In addition, 2 series and 7 series also have a small amount of applications. The 2 series copper aluminum alloy has a higher hardness and can be used in some bodywork sheet metal parts; the 7 series is mainly used in the fields of aerospace and military engineering, and is superhard, corrosion-resistant and wear-resistant. Of course, the price of the material is also very impressive. At present, the domestic 7 series aluminum materials mainly rely on imports. Therefore, 7-series aluminum alloys will only be used in critical areas. For example, Wei-lai es8 will only use 7003 aluminum for longitudinal beams, and the rest will use conventional 5 series, 6-series, and aluminum castings (hdpc).
Knowing these many misunderstandings does not exist, at least knowing that aluminum is not equal to pure aluminum. Different aluminum alloys have different characteristics, but aluminum alloys used in the structural field have a common feature of high strength, and their hardness is generally stronger than that of stainless steels of the same specifications. For example, 6 Series t4 aluminum alloys for general body use are After coating and drying, the yield strength is above 200mpa, while spcc/dc04 is also 150-160mpa. In addition, the aluminum body is not a whole, and different types of materials will be distributed according to the force conditions of different parts of the body (the figure below, or Weilai es8, the distribution of its aluminum alloy body in different materials), generally through self-piercing rivets, laser Welding, bonding and other means of connection, the legendary hit the whole body is not the case of waste, can be replaced by professional tools to replace the damaged part, of course, more expensive is true.
What are the advantages of aluminum body?
Do not think too much about us? Congratulations are still a result of its lightweight effect of steel density is 7.8, while the density of aluminum is 2.7, the traditional car in the body about 30-40% of the weight of the vehicle, using high-strength steel to replace ordinary steel The weight can be reduced by about 11%, while the use of aluminum alloy can reduce weight by about 40%. Aluminum alloy can use more than 500kg in a vehicle. The effect is that the vehicle weight can be reduced by about 40%. For example, the fourth-generation Land Rover Range Rover released in 2012 is the first introduction of the all-aluminum body concept for the Range Rover series. This generation of Range Rover is 39% lighter than the third-generation model, and has successfully lost 350kg. By subtracting the weight of five adult males from the car, the benefits of aluminum lightweight body are self-evident, and the performance, fuel economy and handling performance will be greatly improved.
If the strength of the car body is increased and the strength of the safety theory is enhanced, the aluminum alloy will be slightly inferior to the steel plate, but the low density makes the aluminum alloy have greater advantages. The equal strength steel plate and the aluminum alloy have a thickness ratio of 1:1.4, and the weight ratio is only 1: 0.5 means that aluminum alloy can achieve the same strength with only half the weight. The aluminum plate used in general aluminum bodies is 0.2-0.5mm thicker than ordinary low-carbon steels. By increasing the thickness, it is possible to achieve higher body rigidity and torsional resistance than high-strength steels.
This is directly linked to the previous two points in terms of improved handling. Lighter weight can reduce body inertia and increase the thrust-to-weight ratio. Power performance at the same power level can be greatly improved. After increasing the body's rigidity and torsion resistance, it is equivalent to the body's increased effect of reinforcing the tie rod, which can leave more room for the suspension adjustment and increase the limit of the body. In addition, all-aluminum vehicle models are generally optimized for chassis suspension. For example, few aluminum body models swing back to steel, while all-aluminum suspension components can reduce the unsprung mass and have a certain amount of control lift. help.
Superior corrosion resistance Aluminum itself is not stable and is easily oxidized. However, aluminum oxide forms a dense oxide layer on the surface, and it is firmly bonded to the substrate. The high stability can form a tight protection for the aluminum matrix. And in a humid atmosphere, this protective layer can be thickened. However, because of the surface properties and electrical conductivity of aluminum, the aluminum body coating process is also very special, the electrophoresis tank fluid should be replaced frequently, the cost will be higher.
Even better plasticity can't help but mention that aluminum alloys can create extremely beautiful car body surfaces, such as the Jaguar c-type, d-type, and the aluminum body of the U.S. auto e-type. Rich and beautiful, and this kind of Linglong embossed surface modeling, at the time of the technology, steel is extremely difficult to make. Of course, today's stamping and sheet metal technology has allowed steel to exhibit complex surfaces and even sharp corners (Audi is a good example). However, there are still many vehicles that are designed with aluminum alloy in the hood and other locations. However, this is already in the category of body panels and has nothing to do with the body.
After talking about the characteristics of the aluminum body, let's talk about the current situation of the aluminum body in the industry and the reasons behind these situations.
The expensive is still the problem of the aluminum body
Why is the proportion of all-aluminium bodies on the market today only 1% when the performance advantages of all-aluminum bodies are clearly dominant? Very simple, expensive is still the main reason.
On the one hand, the smelting of pure aluminum and the processing cost of aluminum alloy are both higher than that of steel, and the price of aluminum alloy itself is higher. On the other hand, the processing technology is more complicated, and the insolubilization of aluminum oxide in the process of melting and welding of aluminum alloy hinders the filling of metal. Wet, will form cracks, need to be achieved through friction stir welding and laser fusion welding technology. In places that are not suitable for welding, it is necessary to use a joint with a will and an adhesive. For example, the all-aluminum body of the Jaguar XE vehicle requires more than 2,000 rivets, and the use of adhesives also requires the treatment of the surface oxide layer to ensure adhesion, resulting in higher environmental requirements and higher costs.
In general, an all-aluminum body will use self-piercing rivets, hot melt tapping screws, aluminum resistance spot welding, cold metal welding, laser welding, and adhesive bonding. Several or even all processes are used. The complexity of the production process and the degree of automation are required. Far more than traditional bodywork.
To sum up, the aluminum body is not only the higher cost of the material itself, but also the threshold of the manufacturing process is much higher than that of the steel body. Therefore, all-aluminum body models may not be able to reach the level of super running, but it is not economical. For example, Audi's asf all-aluminum frame was only used on previous generations of a8. Other models below could not cover this cost, and the new generation of a8 also gave up the concept of aluminum, and they still used the place where they felt appropriate. High-strength steel.
New energy boosts the development of aluminum bodies
A good news is that the advent of the era of electric vehicles may lead to great development of all-aluminum bodies. Currently under the guidance of policies worldwide, traditional car companies and emerging brands have invested in the ranks of electric vehicles. This trend has been irreversible. By using an all-aluminum body on an electric vehicle, the vehicle weight is reduced by 10%, and the power consumption can be reduced by 5.5%, thus increasing the mileage by 5.5%. The increase in battery costs for achieving the same mileage increment is much higher than this. Therefore, compared to the fuel-saving vehicles, the weight saving effect is not significant, and the lighter weight makes the mileage of electric vehicles more meaningful. For example, the Volkswagen e-golf succeeded in reducing the weight of 187 kg by using an all-aluminum body, while at the same time optimising the battery configuration, the cost was reduced by 635 euros.
At present, entry-level electric vehicles in the market are generally not high in cruising mileage, and are more used for urban commuting. Take the high-end line of BMW i series directly on the carbon fiber body, the chassis structure of aluminum alloy material, has launched the i3 and i8 prices are more moving. Then there is the all-aluminum Tesla model s/x and Weilai es8, and the more introductory model 3 has given up the all-aluminum body and uses a lower-cost aluminum/steel hybrid material. In the foreseeable future, the cruising range will be one of the important indicators of pure electric vehicles for a long time. The weight loss of hundreds of kilograms brought by the aluminum car body will inevitably be a high priority for high-end electric vehicles, and the aluminum car body will be more important. A wide range of applications may be able to help this technology to reduce costs, and gradually sink into the more advanced models in the future.
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