Automobile Lightweight Technology: Development Trends of Aluminum/Magnesium Alloys and Their Forming Technologies

1. Overview:

  • Title: Automobile Lightweight Technology: Development Trends of Aluminum/Magnesium Alloys and Their Forming Technologies
  • Authors: Fu Penghuai, Peng Liming, Ding Wenjiang
  • Publication Year: 2018
  • Journal/Conference: Strategic Study of CAE
  • Keywords: automobile, lightweight, aluminum alloy, magnesium alloy, forming technology, development trend

2. Background:

China is facing severe energy consumption, safety, and environmental problems due to continuous increases in vehicle production and ownership. Vehicle lightweighting technology is crucial for the sustainable development of the automotive industry, improving fuel economy, and reducing emissions. Lightweighting technologies comprise three primary components: lightweight designs, lightweight materials, and lightweight manufacturing processes. The feasibility of implementing new lightweighting technology depends on its cost-benefit ratio; adoption only occurs when benefits significantly outweigh cost increases. This study focuses on newly developed lightweight aluminum and magnesium alloys and the advancement of aluminum/magnesium forming technologies in the automotive sector.

3. Research Objectives and Questions:

  • Research Objective: To review the development trends of aluminum and magnesium alloys, analyze the obstacles to their application in the automotive industry, and propose solutions to promote their wider use in China's automotive sector.
  • Key Research Questions: What are the development trends of new lightweight aluminum and magnesium alloys and their forming technologies? What are the barriers to their application in the automotive industry? What are the viable solutions to promote the use of aluminum and magnesium alloys in China's automotive industry?
  • Research Hypothesis: The development of new materials, new forming technologies, and new applications can promote the use of aluminum and magnesium alloys in the automotive industry.

4. Methodology:

  • Research Design: Literature review.
  • Data Collection Methods: Review of academic papers and industry reports related to aluminum and magnesium alloys.
  • Analysis Methods: Analysis of development trends of aluminum and magnesium alloys, assessment of barriers to automotive application, and proposal of solutions.
  • Research Scope: Aluminum and magnesium alloys, forming technologies, and automotive applications. Includes research and applications both inside and outside of China.

5. Main Findings:

  • Key Findings: A review of the development of new aluminum and magnesium alloys, new forming technologies, and new applications. Suggestions for solutions to promote the use of aluminum and magnesium alloys in the automotive industry. For aluminum alloys, the development and application of new alloys such as JDA1 and JDA2, new forming technologies like vacuum die-casting and rheo-die casting, and new applications including engine brackets and car bodies were presented. For magnesium alloys, the development and application of high-performance alloys like JDM1-JDM4, new forming technologies such as flow forming, and new applications including engine cylinder heads and car bodies were detailed. Barriers to automotive lightweighting technologies included increased material costs, high R&D and production costs, increased maintenance costs, and insufficient maturity of anti-corrosion and joining technologies for magnesium alloys.
  • Quantitative/Qualitative Analysis Results: Primarily qualitative analysis results were presented.
  • Data Interpretation: Analysis and interpretation of data presented in the paper to understand the trends in the development and application of aluminum/magnesium alloys, identify barriers, and propose solutions.
  • Figure Name List:
    • Figure 1. Engine bracket (chassis system) made from the JDA1 aluminum alloy,
    • Figure 2. Photographs of die cast aluminum alloy V6 engine blocks,
    • Figure 3. Calipers (chassis system) produced by rheo-die casting of semi-solid aluminum alloy and their internal microstructure,
    • Figure 4. Aluminum truck wheels produced via forging & flow forming by the Shandong Meika Wheel Co., Ltd,
    • Figure 5. Microstructure of the die-cast Mg-4A1-4Sm-0.3Mn alloy in the as-cast condition,
    • Figure 6. Production of magnesium alloy wheels via extrusion process,
    • Figure 7. JDM1 magnesium wheel produced by cast & flow forming technology,
    • Figure 8. Engine cylinder head made of JDM1 magnesium alloy
Fig. 1. Engine bracket (chassis system) made from the JDA1 aluminum alloy. (a) Design drawings; (b) and (c) photograph of the casted component.
Fig. 1. Engine bracket (chassis system) made from the JDA1 aluminum alloy. (a) Design drawings; (b) and (c) photograph of the casted component.
Fig. 2. Photographs of die cast aluminum alloy V6 engine blocks.
Fig. 2. Photographs of die cast aluminum alloy V6 engine blocks.
Fig. 3. Calipers (chassis system) produced by rheo-die casting of semisolid aluminum alloy and their internal microstructure. The eutectic Si phases exhibits a fine and dispersed distribution after T6 treatment.
Fig. 3. Calipers (chassis system) produced by rheo-die casting of semisolid aluminum alloy and their internal microstructure. The eutectic Si phases exhibits a fine and dispersed distribution after T6 treatment.
Fig. 4. Aluminum truck wheels produced via forging & flow forming by the Shandong Meika Wheel Co., Ltd.
Fig. 4. Aluminum truck wheels produced via forging & flow forming by the Shandong Meika Wheel Co., Ltd.
Fig. 5. Microstructure of the die-cast Mg-4Al-4Sm-0.3Mn alloy in the as-cast condition; the secondary phase exhibits a clumped distribution.
Fig. 5. Microstructure of the die-cast Mg-4Al-4Sm-0.3Mn alloy in the as-cast condition; the secondary phase exhibits a clumped distribution.
Fig. 7. (a) JDM1 magnesium wheel produced by cast & flow forming technology; (b) the microstructure of the wheel in the as-cast condition, which has a yield strength, tensile strength and elongation of 85 MPa, 138 MPa, and 4.8 %, respectively; (c) the microstructure of the wheel rim after flow forming. In as-flow formed condition, the wheel has a yield strength, tensile strength, and elongation of 278 MPa, 317 MPa, and 8.4%, respectively
Fig. 7. (a) JDM1 magnesium wheel produced by cast & flow forming technology; (b) the microstructure of the wheel in the as-cast condition, which has a yield strength, tensile strength and elongation of 85 MPa,
138 MPa, and 4.8 %, respectively; (c) the microstructure of the wheel rim after flow forming. In as-flow formed condition, the wheel has a yield strength, tensile strength, and elongation of 278 MPa, 317 MPa,
and 8.4%, respectively
Fig. 8. (a) Engine cylinder head made of JDM1 magnesium alloy and (b) surface morphology of the combustion chamber after road tests over 9000 km.
Fig. 8. (a) Engine cylinder head made of JDM1 magnesium alloy and (b) surface morphology of the combustion chamber after road tests over 9000 km.

6. Conclusions and Discussion:

This study analyzed the development trends of aluminum and magnesium alloys and the challenges to their application in the automotive industry, proposing solutions. The development of new materials, forming technologies, and applications contributes to automotive lightweighting. However, high material costs, high R&D and production costs, increased maintenance costs, and the immaturity of anti-corrosion and joining technologies for magnesium alloys pose significant challenges. The Chinese automotive industry needs to focus on material development, manufacturing process optimization, in-depth basic research, and leveraging die-casting processes to overcome these barriers.

7. Future Research:

Further research is needed on fundamental aspects of aluminum/magnesium alloys, developing new forming technologies, and expanding applications to various automotive components. Research on addressing magnesium alloy corrosion and improving joining technologies is particularly important. Collaboration with industry is also crucial for technology commercialization.

8. References:

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9. Copyright:

This document is based on the paper: "Automobile Lightweight Technology: Development Trends of Aluminum/Magnesium Alloys and Their Forming Technologies" by Fu Penghuai, Peng Liming, and Ding Wenjiang.

DOI: 10.15302/J-SSCAE-2018.01.012.

This document is a summary of the paper and its unauthorized commercial use is prohibited.
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