[Alcoa.com] Nowadays consumers are accustomed to considering body shape, engine power, and interior configuration as the main considerations for buying a car, and auto manufacturers also like to use Internet, smart, and electrification as the main development direction. The entire Chinese automotive industry seems to have overlooked a topic that has had a far-reaching impact on the development of automobiles and has been explored around the world for a long time - the reduction in vehicle weight.

As early as the 1980s, aluminum alloy wheels that were lighter and more beautiful than traditional steel wheels became the logo of high-end cars. Today, aluminum alloy wheels have been equipped on a variety of economic family cars, and whether or not it is equipped with aluminum alloy suspension is still a criterion for people to judge "good cars." It can be seen that consumers have long been aware of the use of lightweight materials for automobiles. However, the weight reduction of body frames has not received the attention of consumers. After all, unlike the components such as wheels and suspensions, the body is covered with heavy paint. Face coverage, the only parameters that can be referenced are the “Condition Quality” item on the parameter list.

Compared with car body weight, consumers prefer to take a hundred kilometers of acceleration time of a car, or power output to determine the quality of the car. However, what people do not know is that it is not easy for the manufacturers to increase the power of the engine by 10 horsepower. The improvement of the performance of the vehicle is negligible, but if the power output remains unchanged, if the unsprung mass of the vehicle can be reduced by 10kg, then There is a significant improvement in reducing acceleration, braking, handling, and reducing fuel consumption.

With the ever-increasing car configuration and ever-increasing dimensions, the weight reduction of wheels and suspensions alone has not been able to meet the demand for light weight. Therefore, the weight reduction of car bodies has become the trend of the current car companies. The aluminum car body is A more suitable choice. When you mention the aluminum body, the first thing that comes to mind is necessarily Jaguar Land Rover. Its newer XFL car alloy application rate is as high as 75%, which is a relatively high level in the current industry.

The pride of the all-aluminum body

"All-aluminum bodywork" refers to the use of aluminum alloys on white bodies. Body-in-a-white refers to the body frame structure of the body and does not include four doors and two covers for open and closed parts (front and rear doors, hood, tailgate, or tail). Cover). The effect of weight loss on the white body is obvious - the Jaguar XFL only weighs 297kg. Even if the four doors continue to use steel materials, the Jaguar XFL can still achieve a weight reduction of 190 kilograms for the entire vehicle. The fourth-generation Land Rover Range Rover also uses an all-aluminium body, which has achieved a weight reduction of nearly 200 kg.

Compared with models that have only been fully aluminized on body panels, the use of all-aluminium-white bodies is more effective in reducing weight, and it is also more difficult to manufacture and costs more. At present, some of the large and medium-sized luxury cars on the market are still made of steel-aluminum-alloyed steel-based body materials. Jaguar XFL alone insists on the use of aluminum alloy as the main material.

More targeted aluminum alloys

Compared with the traditional steel body, the aluminum alloy body frame has the disadvantage of insufficient strength. However, Jaguar Land Rover has been advocating its aluminum alloy body has a variety of advantages, then where does it come from? We know that the body with 100% pure aluminum does not exist, and industrial aluminum is an alloy that is made by mixing various elements. Therefore, the content of various elements creates different aluminum alloy materials with different properties and applicable to different parts.

As the main supplier of aluminum for Chery Jaguar Land Rover, Novelis of the United States developed a special RC5754 high-strength aluminum alloy with a yield strength of 105-145 MPa. It has strength, corrosion resistance, connectivity and formability. Outstanding performance was applied to the body structure of Jaguar XFL; AC600 aluminum with higher yield strength (up to 110-160Mpa) was applied to the body reinforcement; and in the anti-collision beam structure, AC300 was adopted. High-strength aluminum alloy, this type of aluminum alloy yield strength of 180-220Mpa, has reached the level of high-strength steel (210-550Mpa).

Use body riveting glue technology

The extensive use of aluminum alloys in the body of white will encounter problems that do not exist in conventional steel bodies. Because of the different physical properties of steel and aluminum, the traditional welding technology is difficult to ensure the effective connection of different materials, so Chery Jaguar Land Rover introduced the body riveting technology, this technology not only solves the aluminum alloy connection problems, but also significantly increase the body strength.

The riveting technology does not need to reserve a hole. The servo motor provides power to press the rivet directly into the plate to be riveted, and the pressure is as high as 60-80 KN. The riveted sheet plastically deforms under the pressure of the rivets and the rivets and fills the rivets. The body constructed in this way has a higher fatigue resistance and static fastening force.

Due to the different metal potentials of aluminum and steel, it is necessary to fill the rivets with adhesives. By visualizing the glue monitoring system, key process parameters such as length, diameter, and trajectory of the adhesive can be monitored in real time to ensure the precise position of the adhesive. In addition, the use of adhesives can increase the strength of the body connection to 2 to 3 times the riveting strength.

The more aluminum, the better?

The lightweight advantages of aluminum bodies have not been elaborated, but their shortcomings are also obvious. It cannot be avoided that the strength of aluminum alloy materials is lower than that of steel materials. Even if high-strength aluminum materials such as AC300 are used on the anti-collision structure, the strength is still different from that of high-strength steel used in traditional automobiles. The aluminum of the cover is weaker. When a slight collision accident is encountered, the cover member is easily deformed, and the possibility of deformation of the frame member with higher maintenance cost is also greatly increased. Therefore, at present, most car companies still dare not to use aluminum alloy material on the white body.

The use ratio of aluminum alloy is not as high as possible, but the use of reasonable materials in a reasonable position is the correct direction of development. For example, the BMW new generation 7 series adopts steel, aluminum and carbon fiber composite materials on white bodies to reduce body weight while ensuring structural strength and torsional rigidity of the vehicle body; on the other hand, it has higher strength and higher strength than aluminum. Lighter weight magnesium alloys have gradually expanded their application to body parts. Magnesium alloys can be used in clutch housings, gearbox bodies, and engine front covers.

Conclusion:

Aluminum alloy has been used in the industrial field for a long time. It is not a high-tech metal in itself. It has been applied to the body technology to a large extent, and it is more concerned with the coordination of different materials, adjustments, and cost control. In this regard, Jaguar Land Rover is undoubtedly doing a better job. In the process of localization, it can introduce important all-aluminum body shops into the country. It is also a major advancement for the development of the domestic automobile industry.

Compared with the traditional steel body, the all-aluminum body still has drawbacks, but it cannot stop it from becoming the mainstream of future body materials. The Jaguar Land Rover also regards the aluminum body as its own brand totem, which has a great promotion effect for its marketing promotion. If Jaguar Land Rover can continue to explore the use of body materials along the momentum of the all-aluminum body and become the leader in automotive lightweight technology, it is estimated that it will win more respect from the industry.

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