Motor Fan illustrated

Special Feature / Automobile Technology

The more technologies are revealed, the more interesting cars become.

Aluminum Material for Automobiles The environment-friendly metal underpinning Hiroya YAMAGAMI/AUDI/BMW/DAIMLER/JAGUAR/MAZDA/TESLA MOTORS/TOYOTA/Motor Fan illustrated and UACJ and illustrated Fan MOTORS/TOYOTA/Motor YAMAGAMI/AUDI/BMW/DAIMLER/JAGUAR/MAZDA/TESLA : Hiroya & FIGURE PHOTO next-generation automobile development

The issue of how to reduce CO2 emissions through the improvement of fuel ef ciency has become the top priority in automobile development. One major solution is to reduce the weight of vehicle bodies…and that is precisely why aluminum is now garnering a great deal of attention. Its speci c gravity is only 2.7, compared with 7.8 for steel. Aluminum, a tough high-speci c strength material, has many other merits. It is highly corrosion-resistant, readily formable, and environment-friendly because it is easily recycled. What’s more, it’s a very attractive material for use in vehicles. Aluminum is increasingly being used for structural components, body panels, and a wide range of other parts, and signi cant advances are being made in forming and joining techniques, as well as in the development of aluminum alloys. Aluminum… Without doubt, it will become an increasingly indispensable material in automobile development.

The largest manufacturer of rolled aluminum products in Japan, Tokyo Sankei Bldg., Otemachi 1-7-2, Chiyoda-ku, Tokyo, 100-0004 Japan UACJ was established by the integration of Furukawa-Sky Telephone: +81-3-6202-2667, Telefax: +81-3-6202-2032 Aluminum Corp. and Sumitomo Light Metal Industries, Ltd. www.uacj.co.jp/english/ [email protected] Use of aluminum alloys in automobiles 1 Bulkhead B pillars Roof Trunk lid Aluminum alloy sheet Also called the firewall, this is a wall used to These support the roof and The roof panel features a structure that As with the bonnet, separate the passenger compartment from 6000 series aluminum alloys are door latches, and also absorb bears the stress of the forces acting on the use of aluminum the engine room and the trunk. used for body panels, bonnets, the impact of side collisions. each of the pillars. The roof area is alloys for trunk lids doors, roofs, etc. They are highly large, so changing from steel to alloy is also making good BODY CHASSIS formable and have low-yield & works as well as for the bonnet. progress. Aluminum alloy sheet strength in the forming process, Aluminum extruded shapes but feature high bake Automobile fuel ef ciency standards around the world are Aluminum cast products hardenability, meaning they becoming increasingly strict in response to global warming. become high-yield strength after In Europe, legislation is currently being prepared with the aim of the coat baking process.

setting new-vehicle CO2 emission standards for 2020 at 95g/km. The key to achieving this is the use of materials that help reduce Aluminum extruded shapes the weight of vehicle bodies. There are commonly used for parts that require a uniform Thanks to improvements in the strength and workability of A pillars & roof pillars cross-sectional shape, strength, lightweight aluminum alloys, aluminum’s use in vehicle bodies is These connect with the roof and rigidity such as bumpers, now moving into high gear. side railings and support side members, side sills, etc. the upper body. They play 5000 and 6000 series aluminum an important role as a collision crumble zone. alloys are most commonly used, and 7000 series aluminum alloys Body side panels when more strength is required. Motor Fan illustrated Fan Motor illustrated Fan Motor These are structural parts that form the Aluminum cast products Front fender structural skin of the vehicle. These commonly include The front fender is not Audi A8 subjected to stress. This cylinder blocks, transmission cases, and wheels, but ALUMINUM The Audi A8 is the rst was one of the earliest ALUMINUM parts to be created from mass-market car with an moldings are also used in body aluminum alloy sheet. components. The use of aluminum chassis. aluminum alloy die casting is AUTOMOBILE TECHNOLOGY AUTOMOBILE TECHNOLOGY AUTOMOBILE The vehicle features a appropriate when creating parts unique Audi Space Frame with complicated structures that structure with the upper require a high level of strength. body connected onto an underbody frame base.

Doors Front side members These are constructed from internal These are connected and external sections. The internal to the subframe. sections are often made from 5000 02 In addition to series aluminum alloys, while the 03 Bonnet (outer) load-bearing, they external sections are often made Crossmembers from 6000 series aluminum alloy The bonnet has a double-layered are designed to Side impact beams sheet. interior/exterior structure. This is absorb the impact of These extend across the largest exterior panel on the collisions. from the side sills in a These absorb the impact on the doors from side vehicle. Bonnet (inner) grid pattern. They support the passenger collisions. This part is used to reinforce the outer panel. compartment floor and With collision safety in mind, the panel bear torsional stress. structure is designed to crumple on impact.

A pillars

Rear side members Aluminum alloy space frame | Audi R8 All-aluminum alloy monocoque | Jaguar XE All-aluminum alloy monocoque | Range Rover Sport

This car features a mid-ship layout with a The latest XE is an aluminum alloy monocoque Based on knowhow accumulated through the Front side members B pillars bathtub-shaped monocoque structure that is vehicle based on the common Jaguar/Land development of the Jaguar XJ, this is the first used to provide strength and rigidity to the Rover platform. SUV to feature an all-aluminum body design. Side sills Roof side railing body as a whole. This is a hybrid vehicle body featuring aluminum alloys and CFRP. Use of aluminum in electric vehicles Mercedes AMG GT and hybrid electric vehicles The AMG GT, the agship Aluminum wheels Compressor wheels for turbochargers Mercedes sports car, features Although both cast and forged These are precisely manufactured aluminum an all-aluminum body. The aluminum wheels are used, forged aluminum wheels are alloy impellers used to compress air. UACJ's engine and transmission are lighter and stronger. aluminum precision cast compressor wheels positioned separately, with the hold the world’s top share. transmission in a transaxle position connected to the engine via an aluminum torque tube.

The Audi Q7 e-tron 3.0TDI quattro battery Lithium-ion batteries are now commonly used in note PCs, smartphones and other mobile devices, but capacity-enhancing technologies are rapidly increasing the popularity of their use in automobiles as well. Motor Fan illustrated Fan Motor illustrated Fan Motor

Suspension arms

ALUMINUM As critical safety components, these need to ALUMINUM be highly reliable. The use of high-strength forged aluminum parts is increasing. AUTOMOBILE TECHNOLOGY AUTOMOBILE TECHNOLOGY AUTOMOBILE The Nissan Leaf lithium-ion battery The battery cases and sealing components of Hub carriers lithium-ion batteries, which are the most These components connect important component in electric vehicles, are the suspension arms with made from aluminum alloys, and aluminum foil the brakes and wheels. is used in the current collectors.

Cylinder blocks Cylinder blocks made of 04 aluminum are lighter than 05 cast-iron blocks of the same size. Al-Si-Mg type Brake calipers aluminum alloys, which are suitable for die-casting, are Lithium-ion batteries As these are exposed to high commonly used. temperatures, while also being repeatedly subjected to stress, they need high thermal stability and good abrasion resistance. Subframes A subframe is a structural component that is a separate structure within a larger monocoque. It carries certain components, such as the engine drivetrain or suspension. Subframes Use of aluminum alloys in automobiles 2 need to have high rigidity and shock-absorbing capabilities. Heat exchanger DRIVETRAIN & POWERTRAIN

Almost all cylinder blocks are currently made from aluminum casting, and use of aluminum alloys in TESLA MODEL-S suspension components, which require higher strength, is also increasing. The Tesla Model S uses a bathtub-shape frame made with aluminum alloy extruded shapes, and is equipped with a lithium-ion battery pack. The heat exchangers are also manufactured from an aluminum alloy. ALUMINUM MATERIAL Aluminum alloys used in automobiles : 1 Superplastic aluminum alloy sheet

Superplastic material has elongation Aluminum alloy sheet of more than several hundred Before stretching percent at high temperatures. Using the blow-forming method After stretching Aluminum alloy sheet features superior formability and strength (using compressed gas to force heated material into a metal mold), superplastic aluminum alloy sheet Mercedes Benz S Class permits greater design flexibility. Blow forming The “ALNOVI” superplastic aluminum 6000 series aluminum alloy for body panels Mold Mold alloy sheet developed by UACJ Corporation is widely used in body Approximately Producing body panels from aluminum alloy is a highly Approximately panel production. Ford F-150 400°C to 500°C 400°C to 500°C effective way to reduce weight and enhance fuel efficiency. Compressed gas Currently, 6000 series aluminum alloys are the type most In the F-150’s latest facelift, the body panels were changed to commonly used in body panels, and since they have aluminum, reducing the weight “bake-hardenability,” they can be strengthened after the coat by 320 kilograms and improving baking process. fuel efficiency by 5% to 20% compared to the previous model. 6000 series aluminum alloys are characterized by low strength Aluminum alloy sheet for during press forming, giving them high formability, but the high-strength structural components Motor Fan illustrated Fan Motor coat baking process makes them substantially stronger. Change in proof stress illustrated Fan Motor When shipped After 2% pre-straining from during forming

Proof stress After 2% pre-straining to after coating 20 min. at170°C Aluminum alloy sheet designed for high-strength Bake-hardenability 6000 series sheets structural components is suitable for use in automobile are strengthened Formability more than 5000 framework structures. The 7075 alloy (ultra-super

ALUMINUM Required series sheets. duralumin) features the highest level of tensile strength, ALUMINUM Hemmability properties of proof stress, and fatigue strength. It is used for chassis automobile Dent resistance body sheet 6000 series 5000 series 5000 series 5000 series and subframes. Mazda MX-5

AUTOMOBILE TECHNOLOGY AUTOMOBILE Corrosion resistance Change in proof stress of body sheets The new Mazda MX-5, which weighs TECHNOLOGY AUTOMOBILE less than 1 ton, is a new-generation High-luster paint finish lightweight sports car. The silver-colored Ordinary body sheet parts in the illustration are all produced from aluminum alloys.

Power Plant Frame Bonnet of Toyota Prius This is an original Mazda-developed frame Both the interior and exterior structures are made from 6000 series High-hemmability sheet that increases the rigidity of the drivetrain aluminum alloy sheet. and solidly connects the transmission to the differential housings. The frame is made from 06 UACJ’s high-strength aluminum alloy sheet. 07 Hemming Since aluminum alloy sheet is less elongate than steel sheet, it cracks easily during hemming. This means that flat hemming involving bending by 180 degrees has previously been difficult to Top plate achieve. However, UACJ Corporation has created an aluminum alloy LIB products for EVs and HEVs Negative electrode sheet that can be subjected to Sharp Hemming, a process that is Terminal even more problematic than flat hemming. Proof valve Separator Aluminum alloy materials are also used in LIB products. Aluminum cathode foils They are indispensable in the Aluminum Housing cases Positive electrode materials production of the foil used in Busbars Housing case used in LIB Disclosure sealers the positive electrode, cans, 5000 series aluminum alloy sheets for body panels Laminated pouches busbars, and other peripheral components. 5000 series aluminum alloy sheets are the strongest of the non-heat-treatable Toyota GT86 Bonnet alloys and also have excellent press formability. Through finding the right amount of magnesium to add, and through nanostructure design control, UACJ Corporation has created aluminum alloy sheet that has formability similar to that of steel sheet. Aluminum alloy busbars LIB cell LIB module ALUMINUM MATERIAL Aluminum alloys used in automobiles : 2 ALUMINUM MATERIAL Aluminum alloys used in automobiles : 3 Aluminum extruded products Aluminum alloy surface treatment

Components with complex cross-sectional shapes The beautiful transmuting appearance of aluminum with processed surfaces

Aluminum extruded shapes Aluminum Design Sheets Anodizing Self-coloring process 2-step coloring process Using extrusion, it is possible to produce The aesthetically pleasing appearance of aluminum Etching Staining complex shapes. The process involves is one of its major features. The sheen of luminous Surface treatment Pre-coating Surface property Surface design heating the aluminum alloy up to 400-500°C aluminum alloys can be further enhanced through Printing and pressing it through a die. Various electrolytic and chemical polishing, and they are Plating shapes can be extruded, including complex used for decorative parts, such as vehicle moldings. shapes and hollow materials. They are Lotus Evora Various surface treatment technologies can be used normally used for automobile subframes Extruded 6000 series aluminum alloy to accentuate the aesthetic qualities of aluminum. components are bonded using and bumper beams. self-piercing rivets and adhesive material. Motor Fan illustrated Fan Motor illustrated Fan Motor

Aluminum Design Sheets Anodizing

ALUMINUM Aluminum alloy panels are commonly used for interior Anodizing is a process that involves ALUMINUM Die Billet decoration, such as in the center console, door trim, turning a piece of aluminum into an and other parts of the Infiniti Q50. Their surface is anode in an electrolytic solution to

AUTOMOBILE TECHNOLOGY AUTOMOBILE P very smooth, detailed and shiny. create a surface layer of oxidized TECHNOLOGY AUTOMOBILE aluminum. Colored oxide layers can Extruded components are produced using be produced in black, red, blue, etc. 6060 aluminum, and there is a clear Platen Stem Container Block difference in the cross-sectional shape of components formed in this way. The ability Aluminum extruded products are used to produce motorbike to create this kind of shape is characteristic Solid shape of extrusion processing. The red lines in the frames and front forks. UACJ’s photo are adhesive material: a large amount front fork outer tubes hold the world's top share. of adhesive material is used in the Lotus Hollow shape aluminum alloy chassis. Male die Female die Hollow die Evaluation and analysis technologies 08 09 UACJ works on simulations, analysis and evaluations in order to develop better aluminum alloys. Particularly useful for development is impact simulation analysis, fluid analysis and thermal analysis. CAE is used for Forged aluminum alloys considering the characteristics of materials and shapes to improve collision safety.

Forged materials are strong and can withstand being Crash boxes repeatedly subjected to stress, so they are used to produce parts such as aluminum wheels, suspension arms, and brake components, which require a high level Scuff plates of reliability. There are various different forging methods, including hot, cold, open die, and closed die forgings.

Bumpers of the Mazda MX-5 (kN) This bumper is manufactured The crumpling process 30 Experimental value Analytical value using a 7000 series aluminum of crash boxes during Load alloy produced by UACJ collisions is compared 20 using experiments and Corporation for use in hollow (Left) Gearshift paddle. (Right) Pedals. Aluminum alloys have CAE. 10 shape extrusions. been used instead of resins for these parts because of their attractive luster and texture. 0 0 50 100 150(mm) Displacement ALUMINUM MATERIAL Aluminum alloys used in automobiles : 4

Tailored blanking Thin sheets Thick sheets

Thick sheets

Pressed to Aluminum alloy joining technologies Aluminum sheet parts Unified through joining create components

Welding, adhesion, and bonding of materials with different properties Comparison of different joining methods

Joining efficiency (speed m/min) Quality Cost

Method Thickness: Thickness: Tensile Formability Device Shielding As the use of aluminum alloys in vehicle bodies has become Bonding of materials with differing properties such as 1 mm/1 mm 1 mm/2 mm property Stretch forming Deep drawing gas common, dramatic advances have been made in aluminum aluminum-iron, and aluminum-resin, is also garnering joining technologies, such as laser welding and friction stir attention. Such joining technologies as these are expected to Base material Base material Base material FSW Not welding. There have also been advances in mechanical joining lead to a considerable increase in the use of aluminum. The first-generation Audi R8 was the first 2.0 ~ 4.0 2.5 ~ 3.5 fracturing part part Medium needed such as riveting, screwing, and clinching, and the use of mass-market automobile to employ tailored blanking. (5000 series) fracturing fracturing adhesive materials. Tailored blanking is a production method that involves YAG Base material Base material Base material joining materials of differing thicknesses or qualities laser 2.0 ~ 4.0 2.0 ~ 4.0 fracturing part part Expensive Needed before press forming them. Since it is possible to (5000 series) fracturing fracturing Friction stir spot welding (FSSW) FSW-FSSW position materials of differing strengths, thicknesses, Tool and qualities only where they are required, the method Arc Base material Welded Base material contributes greatly to weight reduction. welding ~ 1.2 ~ 1.2 fracturing part part Inexpensive Needed

Motor Fan illustrated Fan Motor (5000 series) fracturing fracturing illustrated Fan Motor Friction stir welding (FSW) is a

joining technology that involves Excellent Good Acceptable May require further consideration the use of a tool with a pointed Insertion/joining Withdrawal revolving tip that is pressed against the metal, which is then Brazing

ALUMINUM softened by friction-generated ALUMINUM heat. This plasticized material is Butted surfaces used to join pieces of metal Automobile heat exchangers AUTOMOBILE TECHNOLOGY AUTOMOBILE together. are produced by assembling TECHNOLOGY AUTOMOBILE Tool This method has many benefits, multi-hole flat tubes and including low levels of distortion corrugated brazing sheets. and residual stress, and less To reduce weight and Joined section significant reduction in strength Pin enhance performance, heat when exposed to heat. FSW (aluminum and copper) exchanger materials are made thinner, so corrosion proofing is vital. 10 Intercooler: Nissan GT-R 11 AUDI TT Joining technologies

Punch riveting Laser welding Adhesion

Two sheets are A laser light is joined by forcing pointed at the a wedge-shaped parts to be High-adhesive strength rivet through joined to weld pre-coated aluminum alloy sheet them. them together. The green, blue, and red parts shown Aluminum alloy sheet material with a here are made from aluminum alloy. coating that is highly adhesive to resin is used to support the weather strip. Cockpit cross-car beam created by joining aluminum alloy and resin. Flow drill screwing Self-piercing riveting Mechanical clinching

KO treatment sheet: A method of The leg portion A die is used to Adhesive pre-coat screw fastening distorts and clinch materials high-adhesion aluminum aluminum alloy sheet in which the cuts into the together from sheet surface processing fastening member base materials above and below. Dendritic porous layer Polypropylene 200 nm to 250 nm can be removed. to fasten them UACJ Corporation’s KO resin together. processed aluminum sheet is covered with a high-adhesion Barrier layer oxide layer with a complex porous 10 nm to 20 nm Weather strip and dendritic configuration. Alloy denomination Characteristics Use in automobiles Aluminum usage guidelines AA UACJ

The table on this page explains the characteristics of the different alloys types and what automobile GC45 High-strength, high-formability body panel material. Bonnets, roofs, doors, pillars, oil pans, floors, 5022 components they are used in. TG19 Low coat-baking proof stress reduction. rear fenders, air cleaner housings

GC150 A slightly stronger alloy than GC45. Body panels

GC55 Bonnets, roofs, trunk lids, instrument panels, 5000 5023 Body panel material with further enhanced formability. Alloy denomination Al-Mg TG25 seat buckets, knee protectors Characteristics Use in automobiles AA UACJ A high brightness alloy with the same strength as 3003. Moldings, trims, reflective panels, 5110A 257S Excellent processability and surface treatability. Good deep-drawability and corrosion resistance. headlamp bulb shades 1050 A50 Heat insulators The most corrosion-resistant of all aluminum alloys. 1000 A non-heat-treatable alloy for welded structures. Brake pistons, fuel delivery pipes, Al 1100 A30 Heat insulators, license plates 5056 356S General-purpose aluminum with over 99.0% purity. Excellent seawater resistance. airbag inflators Surface appears slightly white after anodizing. 1200 A0 Heat insulators SG112 2014 14S Motorbike handles, ABS SG212 Body panel alloy with high bake hardenability, TM30 formability, and high-hemmability. Very strong alloy used for structural components. Because of 2017 17S TM55 relatively higher copper content, inferior corrosion resistance. Bonnets, rear fenders, front fenders, pillars, Shock absorbers, handles, spokes, conrods wheel housings, roofs, doors 2024 24S SG312 BH type body panel alloy. TM66 High-strength, excellent properties at high and low temperatures, Even stronger than SG112 with good formability. 2000 TM67 Al-Cu 2219 B19S superior weldability, but inferior corrosion resistance. Rotors, brake components Motor Fan illustrated Fan Motor illustrated Fan Motor CG29 Higher strength at elevated temperatures than that of 2618. Conrods, pistons 61S ABS, crossmembers, wheels, propeller shafts, 161S arms, links, air bags, joists, receiver tanks CB156 6061 Heat-treatable alloys with good corrosion resistance. CB256 Lead-free highly-machinable alloys. AT valves 561S Power plant frames KS26

ALUMINUM 303S 10% stronger than 1100. ALUMINUM 3003 Piping 6000 6013 SG210 High-strength aluminum alloy for forging. Suspension arms D3S Good processability and corrosion resistance. 3000 Al-Mg-Si Al-Mn 304S Stronger than 3003. 63S AUTOMOBILE TECHNOLOGY AUTOMOBILE Typical extrusion alloys. Lower strength than 6061, Moldings, seat frames, truck bed gates, TECHNOLOGY AUTOMOBILE 3004 Cowl grilles, heat insulators 6063 163S 4S Excellent deep-drawability, and good corrosion resistance. but superior extrusion properties. roof railings, piping Y63 Excellent heat and abrasion resistance. 4032 32S Pistons Low thermal expansion coefficient. 465S Intermediate strength between 6061 and 6063. Bumpers, space frames, engine brackets, 6005C L55 Good corrosion resistance and weldability. seat frames, ABS, side sills, shock absorbers SC100 Excellent abrasion resistance and forgability. Stronger than 4032.

High-strength alloy with good bendability and corrosion SC300 A stronger version of SC100. SG109 Bumper reinforcement, space frames 4000 Power steering housing, resistance. Hollow extrusion is possible. Al-Si compressor scrolls, valve lifters TF06B Excellent abrasion resistance and forgability. TF08 Stronger than 4032. SG310 The strongest of the 6000 series alloys. Wheels, propeller shafts, arms, links 12 TF10B 13 SC150 GT209 A hypereutectic alloy with enhanced forgability. Compressor rotors Lead-free high-machinability alloy. AT valves TF12B KS69S

A medium-strength alloy. Good corrosion resistance and Meter display panels, AT drums, 5052 52S 7075 75S Typical high-strength alloy for use in aircraft manufacture. Seatbelt hinges, links, bobbins, retractors formability. High fatigue strength. air bag inflators, covers

5454 D54S 20% stronger than 5052. Good corrosion resistance. Wheel rims, suspension components 7178 A78S The strongest aluminum alloy. Keys

An alloy for use in welded structures. 183S Bumper reinforcement, seat sliders, The strongest of the non-thermally treated alloys. ZK60 An extrusion alloy for welded structures. 7003 motorbike frames, door impact beams, Tanks, gas cylinders K73 Better extrusion properties than 7204. A high formability version of 183S. motorbike rims 5083 383S Excellent superplastic properties. ZK141 Steering components, crossmembers, 483S 7204 An extrusion alloy version of 183S. Lashing rails K70 Alloys for welded structures. The strength at the welded part brake pedals 5000 NP5/6 7000 recovers almost to the same as that of the raw material by Al-Mg Al-Zn-Mg natural aging. Nearly as strong as 5083. Good processability and corrosion Dust covers, seat frames, air cleaner cases, ZK147 A82S 7204 Jacks resistance. spring sheets K70Y 5182

GM145 Good formability and stress corrosion cracking performance. Body panels (interior) ZK55 Even stronger than 7204. Bumper reinforcement, impact beams, 20% stronger than 5052. Welding and hollow extrusion is possible. motorbike frames and rims A154S Good formability. 7046 ZK170 5154 Wheels, underbody components, 20% stronger than 5052. A254S drivetrain components, 7050 ZG62 Good stress corrosion cracking performance. suspension components High-strength aluminum alloys. Motorbike front forks GC32 Good formability and stress corrosion cracking performance. ZC88

Alloy denominations: “AA” means the denominations used by the Aluminum Association. Basic aluminum alloy information The general properties of aluminum alloys Lightweight, strong, corrosion-resistant, highly formable, and featuring a beautiful surface, 1000 series aluminum 5000 series alloys a great variety of aluminum alloys are used in automobile production. This refers to pure aluminum materials: 1100 and 1200 are the 5000 series alloys with relatively low levels of Mg are used as most common types. 1050, 1070, and 1085 indicate that they decorative materials, etc., and those with relatively high Mg have a purity of at least 99.50%, 99.70%, and 99.85% levels are used for structural materials. aluminum respectively. Typical of the alloys with a moderate amount of Mg is 5052. It Aluminum alloys can be roughly divided into wrought Wrought aluminum alloys are processed by rolling, 1000 series aluminum is not a high-strength material, but it is the most versatile. The alloy 5083 contains a large amount has excellent corrosion resistance and formability, and of Mg and is the strongest of the non-heat-treatable alloys. alloys and cast alloys. These two categories can be extrusion, etc., into a wide range of different shapes, because it also has a highly lustrous surface it is often used Also being suitable for welding, it is used for welded further divided into heat-treatable alloys and including sheets, foil, shapes, tubes, and bars. for decorative parts, nameplates, re ective plates, etc. structural materials in boats, automobiles, chemical plants, non-heat-treatable alloys. The properties of aluminum alloys change with the types The material also features excellent electrical conductivity etc. It performs well in environments exposed to seawater or There are two different types of cast aluminum alloys: and amounts of added elements. and heat-conductivity, and 1060 and 1070 are often used for pollution. power lines and heat dissipation materials. sand mold/metal mold alloys and die-cast alloys. 6000 series alloys 2000 series alloys 6000 series alloys have medium to high strength and good Representative alloys in this series are 2017 and 2024, which corrosion resistance. are known as duralumin and super duralumin respectively. The 6061-T6 alloy has a proof stress of over 245N/mm2, Aluminum alloys They are almost as strong as steel. meaning it is a high-strength alloy comparable to ASTM A36 On the other hand, they include copper, so they are relatively (JIS3101 SS400) structural carbon steel. lacking in corrosion resistance, and when used in corrosive The 6063 alloy is excellent material for extrusion, and it is Wrought aluminum alloys Cast aluminum alloys environments they therefore require anti-corrosion treatment. widely used as a construction material, particularly for 2014 is commonly used as a high-strength forged material. window frames. 2000 series alloys are highly machinable. 2011, in particular, is Sand mold/metal mold alloys Die-cast alloys commonly used for machine components due to its high 7000 series alloys machinability. The 7000 series alloys can be divided into two groups:

Motor Fan illustrated Fan Motor Non-heat-treatable alloys Heat-treatable alloys Non-heat-treatable alloys Heat-treatable alloys Heat-treatable alloys Al-Zn-Mg-Cu alloys, which are the strongest of all aluminum illustrated Fan Motor 3000 series alloys alloys; and Al-Zn-Mg alloys, which are used for welded Pure aluminum Al-Cu alloys Al-Si alloys Al-Cu-Mg alloys Al-Si alloys The representative alloy in this series is 3003, and the structural materials. (1000 series) (2000 series) addition of Mn means it is an alloy that retains the formability 7075, one of the leading Al-Zn-Mg-Cu type alloys, is used in Al-Mn alloys Al-Mg-Si alloys and corrosion resistance of pure aluminum while boasting aircraft and trains. Al-Mg alloys Al-Cu-Si alloys Al-Si-Mg alloys (3000 series) (6000 series) increased strength. It is commonly used for utensils, 7204, one of the leading Al-Zn-Mg type alloys, is strong, and

ALUMINUM containers and as a building material. room-temperature age hardening means that welded parts ALUMINUM Al-Si alloys Al-Zn-Mg alloys Al-Si-Cu-Mg alloys Al-Mg alloys The 3004 and 3104 alloys are based on the 3003 alloy but recover to a strength similar to that of the base material, (4000 series) (7000 series) contain approximately 1% Mg to further increase their giving it superior joining efciency. strength. They are used for aluminum cans, roof cladding,

AUTOMOBILE TECHNOLOGY AUTOMOBILE Al-Mg alloys TECHNOLOGY AUTOMOBILE Al-Si-Cu alloys Al-Si-Cu alloys (5000 series) door panels, etc. Other alloys Since the addition of Li to aluminum makes it less dense and Al-Si-Mg alloys Al-Si-Cu-Mg alloys 4000 series alloys increases its Young's modulus, it is garnering attention as an The addition of silicon to the 4032 alloy reduces thermal ideal low-density, high-strength material suitable for use in Al-Cu-Ni-Mg alloys expansion and improves abrasion resistance. Forged material aircraft and large structural materials. for pistons also has other trace additives such as Cu, Ni, and New 8000 series alloys are being developed, such as Mg, which enhances heat resistance. internationally registered powder metallurgy aluminum alloys, Al-Si-Ni-Cu-Mg alloys As the melting temperature of 4043 is low it is used for etc. welding wire and brazing ller metals. Thanks to the dispersal Al-Si-Cu-Mg-Ni alloys of Si particles, 4043 also has a beautiful gray coloring when 14 anodized. 15

The International Alloy Designation System BACK NUMBERS

Rolled aluminum alloys are classified in There are currently more than 400 reasonable to say that rolled accordance with the International Alloy different aluminum and aluminum aluminum alloy specifications are Designation System (IADS) based on an alloys registered and administered more internationalized than those of agreement to which 22 countries and by the system. any other metallic material. Cast 24 organizations are a party. Four-digit The European standard ENAW-5052 aluminum alloys, on the other hand, code numbers are used to identify alloy and the Japan Industrial are still not subject to an international alloys, and the various alloys are Standard A5052 alloy share the alloy registration system like the one precisely classified according to the same four-digit number (5052), and for rolled aluminum alloys. types and amounts of added elements this means that the chemical "Motor Fan illustrated" is a very popular Japanese magazine especially dedicated to and impurities they contain, and their constituents of the alloys are exactly Reference from European Aluminium automotive technologies, materials, car electronics, and production processes. It is a unique publication because it presents technical information using expressive various threshold limit values. the same. For this reason, it is www.european-aluminium.eu terminology, and it is also graphically beautiful, with many photographs and illustrations to enhance the understanding of the articles. As a result, many Motor Fan illustrated enthusiastic non-Japanese readers from all over the world enjoy reading it. Publisher: SAN’EI SHOBO PUBLISHING CO., LTD Motor Fan illustrated has been published for nine years and it is read by automotive 7F Shinjuku East Side Square, 6-27-30 Shinjuku, engineers, university students, and auto enthusiasts. The magazine is supported by Shinjuku-ku, Tokyo 160-8461, JAPAN engineers of JOEM and suppliers. http://www.motorfan-i.com/ The editorial concept of the magazine is: email: [email protected] The more technologies are revealed, the more interesting cars become.