ALUMINIUM ALLOYS IN AUTOMOTIVE

INDUSTRY

E. Kabliman

Outline

• CO2 emission limitis 2020;

• New trends in automotive industry;

• Use of lightweight materials;

• Aluminium alloys classification;

• Recycling of aluminum;

CO2 emission

CO2 limits

http://www.theicct.org/blogs/staff/importance-mandatory-standards http://ec.europa.eu/clima/policies/transport/vehicles/cars/index_en.htm

Automotive industry – new techniques

http://ec.europa.eu/clima/policies/transport/vehicles/cars/index_en.htm

100 kg weight reduction 0,5 l/km

Preis

Electrocar Tesla S

• 95 000$

• Capacity: 85 kw*h

• Distance: 450 km

• 18 kw*h pro 100 km

• 100 km (Russia): 60 rub.

• 100 km (Germany): 180 rub.

Electrocar Mercedes-Benz W221 S

• 105 000$

• Capacity: 90 liters

• Distance: 800 km

• 11 liters pro 100 km

• 100 km (Russia): 340 rub.

• 100 km (Germany): 740 rub.

Reduction of carosserie weight • Use of lightweight metals materials in construction of autobody parts

• Light, but good mechanical properties

Light but not cheap – compromise concept has to be found !

Requirements for used materials

• Low weight;

• Sufficient strength for structural stability and durability,

• Good formability;

• Compatibility with assembly operations;

• Good corrosion resistance;

• Recyclability;

• Low material and fabrication costs;

[1] J. Hirsch, Virtual Fabrication of Aluminium Products. Microstructural Modelling in Industrial Aluminium Production, edited by Jurgen Hirsch, WILEY-VCH Verlag GmbH &

Co. KGaA, Weinheim, 2006

Example: SuperLightCar project

http://www.superlightcar.com/conference/docs/SLC_Kurzfassung_englisch.wmv

Real production up-to-date - 400 kg (2012)

- 208 kgV

http://www.welt.de/motor/article108772455/Autobauer-entdecken-eine-neue-Leichtigkeit.html

Eine vollständig aus Aluminium gefertigte Karosserie wird bereits in

Großserie hergestellt (z. B. Audi A2 und A8, Jaguar XJ, Mercedes Benz

SL oder Opel Speedster). http://de.wikipedia.org/wiki/Karosserie#Aluminium

Lightweight materials

Aluminium alloys classification

Recycling of aluminum alloys

Thank you!