Current Trends in Metallic Materials for Body Panels and Structural Members Used in the Automotive Industry 2024

This paper introduction was written based on the 'Current Trends in Metallic Materials for Body Panels and Structural Members Used in the Automotive Industry' published by 'MDPI'.

1. Overview:

• Title: Current Trends in Metallic Materials for Body Panels and Structural Members Used in the Automotive Industry
• Author: Tomasz Trzepieciński, Sherwan Mohammed Najm
• Publication Year: 2024
• Publishing Journal/Academic Society: Materials, MDPI
• Keywords: aluminium alloy; automotive industry; body panel; steel; titanium alloy

2. Abstracts or Introduction

Abstract: The development of lightweight and durable materials for car body panels and load-bearing elements in the automotive industry results from the constant desire to reduce fuel consumption without reducing vehicle performance. The investigations mainly concern the use of these alloys in the automotive industry, which is characterised by mass production series. Increasing the share of lightweight metals in the entire structure is part of the effort to reduce fuel consumption and carbon dioxide emissions into the atmosphere. Taking into account environmental sustainability aspects, metal sheets are easier to recycle than composite materials. At the same time, the last decade has seen an increase in work related to the plastic forming of sheets made of non-ferrous metal alloys. This article provides an up-to-date systematic overview of the basic applications of metallic materials in the automotive industry. The article focuses on the four largest groups of metallic materials: steels, aluminium alloys, titanium alloys, and magnesium alloys. The work draws attention to the limitations in the development of individual material groups and potential development trends of materials used for car body panels and other structural components.

3. Research Background:

Background of the Research Topic:

The automotive industry is driven by the need to reduce fuel consumption and emissions while maintaining vehicle performance. This necessitates the development and application of lightweight and durable materials for car body panels and load-bearing elements. The industry is characterized by mass production, making material selection crucial based on technological, material, and economic criteria. Historically, steel was the primary material, but the evolution towards lightweight equivalents like aluminium alloys, titanium alloys, and magnesium alloys is ongoing due to environmental concerns and the need for fuel efficiency.

Status of Existing Research:

Existing research and development efforts are significantly focused on Advanced High-Strength Steel (AHSS) grades, driven by projects like the Ultra-Light Steel Auto Body (ULSAB). Work related to the plastic forming of sheets made of non-ferrous metal alloys, particularly aluminium alloys, has also increased in the last decade. There is continuous optimization of steel compositions and microstructures, alongside growing interest in metal-based laminates and hybrid structures combining different materials to achieve desired stiffness and weight reduction.

Necessity of the Research:

The research is necessary to provide an up-to-date systematic overview of metallic materials applications in the automotive industry, specifically focusing on steels, aluminium alloys, titanium alloys, and magnesium alloys. Understanding the current trends, limitations, and potential development trends for these material groups is crucial for guiding future material selection and development efforts in the automotive sector, especially considering the increasing demands for lightweighting and sustainability.

4. Research Purpose and Research Questions:

Research Purpose:

This article aims to present an up-to-date overview of the applications of metallic materials in car body panels and bearing components within the automotive industry. It focuses on the four largest groups of metallic materials: steels, aluminium alloys, titanium alloys, and magnesium alloys. The study also aims to highlight the limitations in the development of individual material groups and potential development trends for materials used in car body panels and other structural components.

Key Research:

The key research areas explored in this paper are:

• Current applications of steels, aluminium alloys, titanium alloys, and magnesium alloys in automotive body panels and structural members.
• Classification and properties of different grades within each material group (e.g., Low-Strength Steels, High-Strength Steels, Advanced High-Strength Steels for steels).
• Processing methods and factors influencing the formability and application of these metallic materials.
• Limitations and potential development trends for each material group in the automotive industry.

Research Hypotheses:

The paper is a review article and does not explicitly state research hypotheses. It systematically reviews and summarizes existing knowledge and trends in the application of metallic materials in the automotive industry.

5. Research Methodology

Research Design:

This research employs a systematic review design. It is a literature review that compiles and analyzes existing research and publications related to metallic materials in the automotive industry.

Data Collection Method:

The data collection method involves gathering information from existing literature, including research articles, industry reports, standards, and publications from academic societies and journals related to materials science, automotive engineering, and manufacturing. The references listed at the end of the paper indicate the sources used for data collection.

Analysis Method:

The analysis method is qualitative and descriptive. The authors systematically reviewed and synthesized information from various sources to provide an overview of current trends, applications, limitations, and future directions for metallic materials in the automotive industry. The paper classifies materials into groups and subgroups, describes their properties, and discusses their applications based on the reviewed literature.

Research Subjects and Scope:

The research subjects are metallic materials used in the automotive industry, specifically for car body panels and structural members. The scope is limited to the four largest groups of metallic materials: steels, aluminium alloys, titanium alloys, and magnesium alloys. The review focuses on the applications, properties, limitations, and development trends of these materials within the automotive context.

6. Main Research Results:

Key Research Results:

• Steels: The paper details the evolution of steel usage from low-carbon steels to advanced high-strength steels (AHSS), including different generations of AHSS (first, second, and third generation). It outlines various steel grades like IF steels, DP steels, TRIP steels, TWIP steels, and Press-Hardened steels, discussing their properties, strengthening mechanisms, and applications in body structures, frames, and reinforcements. Corrosion protection methods for steel are also discussed.
• Aluminium Alloys: The review covers the increasing importance of aluminium alloys due to their low density and corrosion resistance. It classifies aluminium alloys into series (1xxx to 9xxx), detailing their alloying elements, properties, and applications. The paper highlights 5xxx and 6xxx series as most relevant for automotive body components and discusses specific alloys and their applications in body panels, structural parts, and closures.
• Titanium Alloys: Titanium and its alloys are presented as materials with high specific strength and corrosion resistance, suitable for high-performance applications. The paper discusses different grades and classifications of titanium alloys (alpha, alpha-beta, beta), their properties, and applications in exhaust systems, suspension springs, body parts, and frames, particularly in high-end and niche vehicles.
• Magnesium Alloys: Magnesium alloys are highlighted for their extremely low density and high damping capacity. The review discusses the challenges in forming magnesium alloys due to their low plasticity but notes their growing use in drive systems, vehicle rims, brackets, profiles, and interior door components. Specific magnesium alloys and their applications in automotive structures are listed.

Analysis of presented data:

The paper presents data primarily in a descriptive format, supported by tables and figures directly referenced from other publications. Tables list specific grades of steels, aluminium, titanium, and magnesium alloys along with their applications in various car components and references to the source material. Figures illustrate material classifications (steels, titanium alloys), processing methods (QP steel thermal cycle, TWIP steel fabrication), and examples of material applications (Audi AL2 body structure, Bugatti titanium components). Tensile strength and elongation data for different steel grades are presented graphically (Figure 1), and tensile curves for different stainless steel families are compared (Figure 6).

Figure Name List:

• Figure 1. Classification of steels used in the automotive industry(reproduced with permission from Reference [4]; copyright © 2024 Acta Materialia Inc. Published by Elsevier B.V. All rights reserved).
• Figure 2. The influence of bake hardening on stress (reproduced with permission from Reference [78]; copyright © 2024 Elsevier Ltd. All rights reserved).
• Figure 3. Typical microstructure of (a) HSLA and (b) DP steel (reproduced with permission from Reference [31]; copyright © 2024 Woodhead Publishing Limited. All rights reserved).
• Figure 4. Fabrication procedure of the cold-rolled LC/TWIP/LC and IF/TWIP/IF sheets (reproduced with permission from Reference [102]; copyright © 2024 Elsevier B.V. All rights reserved).
• Figure 5. Thermal cycle for the quenching and partitioning process (Ac3-transformation temperature, RT-room temperature), prepared with permission from Reference [132] (copyright © 2024 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved).
• Figure 6. Comparison of tensile curves of selected corrosion-resistant steel families (reproduced with permission from Reference [139] (copyright © 2024 Elsevier Ltd. All rights reserved).
• Figure 7. Aluminium alloy-specific Chinese automotive demand estimates. Top to bottom, the three rows show No-LT (a−c), Middle-LT (d-f), and High-LT (g-i). Three columns show Low-PN, Middle-PN, and High-PN situations from left to right. Where LT = light-weighting-trend and PN = penetration scenario (reproduced with permission from Reference [218]; copyright © 2024 The Author(s). Published by Elsevier B.V.).
• Figure 8. Audi AL2 aluminium body structure (reproduced with permission from Reference [251]; copyright © 2024 Elsevier Science S.A. All rights reserved).
• Figure 9. Baseline part and demonstration part geometry (reproduced with permission from Reference [279]; copyright © 2024, The Minerals, Metals & Materials Society).
• Figure 10. Forming trial results on 7xxx alloy at various forming temperatures (reproduced with permission from Reference [279]; copyright © 2024, The Minerals, Metals & Materials Society).
• Figure 11. The strength of Al–Si alloys, prepared on the basis of data from [209,287-290].
• Figure 12. Classification of the titanium alloys.
• Figure 13. The main applications of titanium and titanium alloys (reproduced with permission from Reference [314]; copyright © 2024, Springer Nature Switzerland AG).
• Figure 14. Bugatti titanium components: (a) eight-piston monobloc brake calliper, (b) active spoiler bracket, and (c) tailpipe trim covers (reproduced with permission from Reference [319]; copyright © 2024 The Authors. Published by Elsevier B.V.).
• Figure 15. Large titanium engine component by Precision Castparts Corporation (reproduced with permission from Reference [320]; copyright © 2024 Published by Elsevier B.V.).
• Figure 16. Development chronologically of titanium parts (reproduced with permission from Reference [331]; copyright © 2024 Elsevier Inc. All rights reserved).

7. Conclusion:

Summary of Key Findings:

The review concludes that steel remains a widely used and cost-effective material, especially AHSS, in automotive manufacturing due to its balance of properties and recyclability. Aluminium alloys are increasingly important for lightweighting, with 5xxx and 6xxx series being dominant. Titanium alloys, while offering superior specific strength and corrosion resistance, are limited to niche applications due to cost and forming challenges. Magnesium alloys offer the greatest potential for weight reduction but face limitations in formability and high-volume production.

Academic Significance of the Study:

This study provides a comprehensive and up-to-date systematic overview of metallic materials used in the automotive industry. It serves as a valuable resource for researchers and experts by consolidating current knowledge on material trends, classifications, properties, and applications. The review highlights research gaps and potential future directions in automotive material science.

Practical Implications:

The practical implications of this review are significant for automotive engineers and material scientists. It offers guidance for material selection based on performance requirements, cost considerations, and sustainability goals. The overview of limitations and development trends can inform future research and development efforts aimed at improving material properties, reducing costs, and enhancing the application of lightweight metals in mass-produced vehicles.

Limitations of the Study and Areas for Future Research:

The study is limited to a review of existing literature and does not include original experimental research. Future research areas identified include:

• Development of technologies for deep drawing of coated materials and materials with desired anisotropic features.
• Further development of AHSS with enhanced strength and formability, including new cold stamping technologies.
• Exploration of cost-effective alternatives to traditional materials for lightweighting to enable broader adoption in mass production.
• Development of mass recycling technologies for composite materials to address sustainability concerns.
• Overcoming formability limitations of magnesium alloys for wider structural applications.

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9. Copyright:

• This material is "Tomasz Trzepieciński and Sherwan Mohammed Najm"'s paper: Based on "Current Trends in Metallic Materials for Body Panels and Structural Members Used in the Automotive Industry".
• Paper Source: https://doi.org/10.3390/ma17030590

This material was summarized based on the above paper, and unauthorized use for commercial purposes is prohibited.
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