Aluminum Alloy - New Lightweight Material for Automobiles

For the sake of environmental protection and energy saving, lightweight is an inevitable trend in the development of automobiles. Lightweight automobiles are critical to reducing body weight, reducing fuel consumption and reducing emissions. Automotive lightweight can be achieved through advanced manufacturing processes, lightweight materials, and structural design. Lightweight materials include aluminum, magnesium, ceramics, plastics, fiberglass, carbon fiber composites, and more.

 

Considering the comprehensive performance of lightweight, energy saving and environmental protection, aluminum alloy is the preferred material for automotive lightweight, and many countries have been committed to the research of automotive aluminum alloy. Studies have shown that for every 1kg of aluminum used in automobiles, 2kg of weight reduction can be achieved; for every 10% reduction in vehicle consumption, fuel consumption can be reduced by 6%-8%, and exhaust emissions can be reduced by 4%.

 

Aluminum alloy materials can be divided into deformed aluminum alloys and cast aluminum alloys. Among them, the deformed aluminum alloy can be used for body system components, heat exchanger system components, vans, etc. Cast aluminum alloy can be used for engine systems, transmission systems, clutch pedals, steering wheels, and the like. Aluminum alloy has high specific strength, corrosion resistance and good formability. After heat treatment, the strength can be compared with steel. Therefore, it can be used as an ideal lightweight material for automobiles. At present and in the future, aluminum alloy materials are lightweight for automobiles. The main choice is alternative materials.

With the increasing weight of automobiles and the increasing demand for aluminum alloys for new energy automobiles, KingTech profile machines also occupy an important position in the automotive industry. KingTech has a mature solution for car parts, bumpers, pedals, sunroof rails, decorative strips and other auto parts processing. Cabinets, large pallet trucks, buses, and battery trays for new energy automobiles can also be deep processed using KingTech equipment. 

Compared with foreign advanced automobiles, the application of China's aluminum alloy panels in the automotive field is still far from the developed countries of the automobile manufacturing industry. In the developed countries of the automobile industry, 18% of aluminum is used in automobile manufacturing. The average aluminum consumption per vehicle is about 140kg, and it is growing at a rate of 20%-30% per year. It is reported that China has introduced relevant policies to support the industrialization of high-quality aluminum alloy automotive panels.

 

In 2018, although China's domestic sales appeared for the first time in years, the annual output and annual sales were the first in the world. In particular, in terms of new energy automobiles, it still maintains rapid development. According to the plan, China’s new energy automobiles will reach 2 million in 2020. For new energy automobiles, lightweight technology is one of the core key technologies, especially in the context of subsidies, how to choose the right route, and also balance performance, battery life and cost, etc. The energy automotive industry is a huge challenge.

 

According to reports, Germany's SGL Carbon announced that it has reached a cooperation with Weilai (NIO). SGL will develop a prototype of a carbon fiber reinforced plastic battery casing for Weilai. The battery casing is 40% lighter than a conventional aluminum or steel battery casing, has high rigidity, and is 200 times lower than aluminum. It is understood that most of the current battery packs for electric automobiles are made of aluminum and steel.

 

In the power battery, the tray takes up 20 to 30% of the weight of the battery system, which is the main structural component. The aluminum alloy material can first meet the structural requirements of the vehicle components, including the battery system, and can replace some of the steel structure materials. Aluminum alloy applications for automobiles mainly include 5××× series (Al-Mg) and 6××× series (Al-Mg-Si), etc. Aluminum trays mainly use 6 series aluminum profiles (material applications, further analysis is needed And groping).

 

As a professional manufacturer of aluminum profile processing centers, KingTech has a complete solution for the processing of battery trays for new energy automobiles. For the processing of rods for battery trays, sheet metal processing, MIG welding, friction stir welding, and assembly processing. Solution, welcome to consult.

The 6 series aluminum alloy has moderate strength, good formability and corrosion resistance, excellent comprehensive performance, low yield strength after solution hardening and natural aging treatment, good stamping formability, and improved strength after baking treatment. The ability is enhanced, so this material is the material of choice for automotive lightweighting.

 

The safety of a car is not measured by the thickness of the iron sheet, but by the safety design of the body structure. In recent years, countries around the world are developing lightweight bodies, reducing displacement, promoting new energy sources, and reducing vehicle weight is the future development trend of automobiles. As an important material for lightweight automobiles, aluminum alloys must be based on the global market and pay attention to its sustainable development for a long time.