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Introduction to Aluminum Use in Automotive the Aluminum Association Presenter

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Introduction to Aluminum Use in Automotive the Aluminum Association Presenter Introduction to Aluminum Use in Automotive The Aluminum Association Presenter Russ Long • Arconic • Chief Engineer – Ground Transportation Products 2018 Aluminum Association Design Seminar Day 1 AM Agenda • Objective: Provide introductory class on aluminum alloys and product forms typically applied in BIW and closure applications. Discussion and examples will compare steel applications to well designed aluminum applications. Specialty applications such as engine castings and transmission parts, aluminum cast or forged wheels, electrical distribution are not included. 1. Value of lightweighting 2. Common automotive aluminum uses 3. Potential weight savings 4. CAFE Overview 5. Current BIW and Closure applications 6. Alloy and temper designations 7. Corrosion 8. Aluminum Repair – “not harder, just different” 2018 Aluminum Association Design Seminar Day 1 PM Agenda 1. Aluminum Sheet Production – 5. Properties after paint bake flowpath 6. Natural aging 2. Aluminum alloys commonly used 7. Formability measures for BIW and Closures 8. Joining – Spot welding, SPR, 3. Sheet Properties Adhesives, flow drill screws, etc. 4. Yield, ultimate and elongations as 9. Design example – aluminum hood, received aluminum door 2018 Aluminum Association Design Seminar Day 2 AM Agenda 1. Extrusion process 6. T4 versus T6 temper 2. Extrusion alloys commonly used in 7. Specialty alloys – crush, high automotive applications strength for bumpers 3. BIW components 8. Geometric limitations and 4. Bumpers, crash boxes guidelines for extrusion design 5. Extrusion alloy properties 9. Design example – bumper 2018 Aluminum Association Design Seminar Day 2 PM Agenda 1. Foundry processes and castings 5. High Integrity evolution​ Aluminum Structural Die Casting​ 2. Casting alloys and designation o Conventional system​ vs. high pressure vacuum die castings​ 3. Foundry metallurgy essentials (101)​ o Case study​ o Requirements and factors 4. Permanent mold and die casting affecting Thin Wall Structural alloys​ Casting​ o 356.2 series, 354, 355, 357, o Properties and tempers F-T4- 359, 413​ T5-T6-T7 6. Joining​ 7. Modeling​ 8. Stress-engineering strain curves 2018 Aluminum Association Design Seminar Dramatic Weight Reduction Across All Applications Potential Weight savings with aluminum – D-class vehicle • 10% reduction in curb weight gives a 6% improvement in fuel economy • Initial customer focus is on advanced closure panels • Customers now developing future Steel (1) Aluminum Typical Wt. % aluminum intensive body structures (kg) (kg) Saving (kg) saving due to greater mass savings potential Hood 16 8 8 50 Fenders 7 3.5 3.5 50 50 kg Deck lid 17 9 8 47 saved Doors 73 43 30 41 BIW 328 209 119 36 2018 Aluminum Association Design Seminar Total 441 273 169 38 All Aluminum Ford F-150 – Launched in 2015 Best in class gasoline fuel economy (19/26 mpg) – 2WD 2.7 L Ecoboost (6 speed) 2018 fuel economy (20/26 mpg) – 2WD 2.7 L Ecoboost (10 speed) Best in class towing 700 - 890 lb lighter performance than 2014 steel model America’s best selling vehicle for over 40 years Contributes to CAFE improvement for the first 2018 Aluminum Association Design Seminar time 2014 Steel F-150 VS. 2015 Aluminum F-150 Comparison Supercrew with 5.5 ft box Length = 5890 mm Wheelbase = 3670 mm Steel Aluminum Wt. % Savings 2014 F150 2015 F150 Savings (kg) (kg) (kg) Hood 10.9 (Alum) 10.6 0.3 3 Fenders 20 7.5 12.5 60 Tailgate 20 9.8 10.2 51 Doors (4) 85 47.6 37.4 44 • Ford F150 is the largest selling vehicle in Cab 283 158 125 43 North America Cargo Box 105 60 45 43 • The P552 is a flagship vehicle Total 524 294 231 44 • Super Duty Trucks (F250, F350, F450) also in aluminum Reference: EuroCarBody 2015, October 21-22, 2015, Bad Nauheim, Germany. 2018 Aluminum Association Design Seminar Weight and Size History • Vehicles have been getting larger, include more features and faster acceleration 2018 Aluminum Association Design Seminar Fuel Economy Regulations – Worldwide Regulations only get tougher moving forward Passenger Vehicle Fuel Economy Fleet Average Passenger Vehicle GHG Emissions Fleet Average 80 270 250 70 230 210 60 EU 190 Japan 50 South Korea 170 China 150 40 US 130 /km (NEDC Test Cycle /km (NEDC Cycle Normalized) Test 110 30 2 Solid Lines = Actual Std. MPG (CAFE Test Cycle (CAFE MPG TestCycle Normalized) Dotted Lines = Estimated Std. Solid Lines = Actual Std. CO - 90 Dotted Lines = Estimated Std. G 20 70 2000 2005 2010 2015 2020 2025 2030 2000 2005 2010 2015 2020 2025 2030 Conversion factor between fuel economy and CO2 emissions: • 8887 g CO2 per gallon of gasoline • 10180 g CO2 per gallon of diesel 2018 Aluminum Association Design Seminar US Corporate Average Fuel Economy (CAFE) standards are size based • How can auto OEMs get to 50 to 60 mpg? I don’t get near this fuel economy with my car! CAFÉ Targets for Passenger Cars 65.0 60.0 55.0 T a 50.0 r 2012 Car target g 45.0 2016 Car target e 2017 Car target t 40.0 2018 Car target m 2019 car target p 35.0 2020 Car target g 2025 Café Target 30.0 25.0 Fiesta Cruze Malibu Chrysler 300 20.0 35.0 40.0 45.0 50.0 55.0 60.0 65.0 70.0 Footprint (square feet) 2018 Aluminum Association Design Seminar US Corporate Average Fuel Economy (CAFE) – light truck targets • What is a light truck? Truck CAFE targets 55.0 50.0 45.0 T a r 2012 Truck target g 40.0 2016 truck target e 2017 Truck target t 35.0 2018 Truck Target m 2019 truck target p 2020 truck target g 30.0 2025 truck target 25.0 Durango F150 Grand 20.0 Cherokee 30.0 40.0 50.0 60.0 70.0 80.0 Footprint (sq ft) 2018 Aluminum Association Design Seminar Drivetrain Alone Cannot Provide the Fuel Savings Required by 2020 Aero Drag Reduction Low Drag Brakes 3.5 – 6% Low Rolling Resistance Tires Mass Reduction (3.5 to 8.5% of Curb Weight) Mass Reduction (1.5% of Curb Weight) Belt mounted Integrated Starter Generator Improved Accessories 5.5 – 9.5% Electric Power Steering Dual Clutch or Automated Manual Transmission 6/7/8-Speed Auto. Trans with Improved Internals Exhaust Gas Recirculation (EGR) Boost Turbocharging and Downsizing Combustion Restart Stoichiometric Gasoline Direct Injection (GDI) 14 – 25% Discrete Variable Valve Lift (DVVL) on OHV VVT - Dual Cam Phasing (DCP) Engine Friction Reduction Low Friction Lubricants Ref: Corporate Average Fuel Economy for MY2012-MY2016 Passenger0 Cars 1 2 3 4 5 6 7 and Light Trucks – Final Regulatory Impact Analysis, NHTSA, March 2010 % Improvement in Fuel Economy 2018 Aluminum Association Design Seminar High Volume Auto Body Evolution Evolution of auto design scenarios Multi-Material Aluminum Intensive Vehicle (Strength & ductility for safety, Robust joining) Tailoring Products MPG Requirements Steel & Aluminum Hybrid Aluminum Closures (High scrap utilization, Steel to aluminum joining) (Increased formability for design/styling) 2018 Aluminum Association Design Seminar Closures NA Penetration 2018 Aluminum Association Design Seminar Grumman LLV US Postal delivery trucks Began production in 1987: Vehicle design life was 24 years and was extended to 30 years in 2009 2018 Aluminum Association Design Seminar Acura NSX All aluminum – 1990-2005 2016 - present 2018 Aluminum Association Design Seminar 2017 Ford Super Duty and Expedition/Navigator Aluminum too!! 2018 Aluminum Association Design Seminar Audi Mixed Material Vehicles Audi A8 Audi Q7 (hybrid steel/alum Aluminum since 1994 Aluminum since 2016 Audi TT Audi R8 Aluminum since 2008 (hybrid steel/alum) Aluminum since 2006 2018 Aluminum Association Design Seminar 2016 Audi Q7 – Hybrid Steel/Aluminum 48% steel / 52% aluminum 2018 Aluminum Association Design Seminar Jaguar/Land Rover Aluminum Vehicles • All Jaguar and Land Rover Vehicles will have aluminum BIW Jaguar XJ Aluminum since 2003 Jaguar XF Range Rover Sport Aluminum since 2008 Aluminum since 1970, 2013 Jaguar XE Jaguar F Type Jaguar F Pace Aluminum since 2015 Aluminum since 2013 Hybrid steel/aluminum 2018 Aluminum Association Design Seminar Ferrari/Lamborghini Aluminum Vehicles Lamborghini Gallardo Ferrari 430 Aluminum since 1998 Ferrari 599 Aluminum since 2003 2018 Aluminum Association Design Seminar Corvette Stingray Aluminum since 2013 Z series aluminum since 2006 2018 Aluminum Association Design Seminar Tesla AluminumTesla Model Vehicles S Electric Vehicle – All Aluminum Model X Model S Model 3 Hybrid steel aluminum BIW 2018 Aluminum Association Design Seminar Mercedes Benz – All Aluminum Vehicles Mercedes Benz SL Roadster Aluminum since 2013 110 kg lighter than steel body Mercedes Benz AMG SLS Coupe Aluminum since 2011 2018 Aluminum Association Design Seminar Mercedes Benz C-Class (2014 to present) 24.8 % aluminum 2018 Aluminum Association Design Seminar Mercedes Benz S-Class (2013 to present) 32% aluminum 2018 Aluminum Association Design Seminar Cadillac CT6 – Hybrid Steel/Aluminum • 62% aluminum – 38% steel Includes all aluminum closures 2018 Aluminum Association Design Seminar Chrysler Pacifica Aluminum hood, sliding doors and liftgate (Mg cast inner) 2018 Aluminum Association Design Seminar 2018 Jeep Wrangler Aluminum hood and doors 2018 Aluminum Association Design Seminar 2019 Silverado Aluminum hood, doors and tailgate 2018 Aluminum Association Design Seminar RAM 1500 Aluminum hood and tailgate 2018 Aluminum Association Design Seminar Daimler Truck Class 8 Cascadia cab Business Class – M2 cab Aluminum since 1992 Aluminum since 2001 2018 Aluminum Association Design Seminar Quiz True or False?: 1. US Government CAFE rules will result in all of us driving small cars. 2. US CAFE rules are more stringent than all other world areas. 3. Aluminum use alone can enable US fleets to meet all CAFE targets. 1. Will EPA/NHTSA dramatically reduce CAFE requirements? 2. What is a typical fuel economy reduction that can be achieved using lightweighting? 3. Are there vehicle classes that will likely use more aluminum? 4. Are aluminum cars as safe as steel cars in crash situations? 5.
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