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Introduction to Aluminum Use in

AutomotiveThe Aluminum Transportation Group

2019 Aluminum Transportation Group

Russ Long

Arconic

Chief Engineer – Ground Transportation Products

Presenter


Day 1 Agenda – Introduction

• Value of lightweighting

• Common automotive aluminum uses

• Potential weight savings

• CAFE overview

• Current BIW and closure applications

• Alloy and temper designations


Day 1 Agenda – Aluminum Sheet Use

• Aluminum sheet production –

flowpath

• Aluminum alloys commonly used for

BIW and closures

• Sheet properties

• Yield, ultimate and elongations as

received

• Properties after paint bake

• Natural aging

• Formability measures

• Joining – spot welding, SPR,

adhesives, flow drill screws, etc.

• Design example – aluminum hood,

aluminum door


Day 1 Agenda – Extrusion Use

• Extrusion process

• Common auto applications

• BIW components

• Bumpers, crash boxes

• Extrusion alloy properties

• T4 versus T6 temper

• Specialty alloys – crush, high

strength for bumpers

• Geometric limitations and guidelines

for extrusion design

• Design example – bumper


Day 2 Agenda – Extrusion Fabrication• Extrusion process (review)

• What is post-extrusion processing?

• Machining

• Joining

• Bending

• Coating

• Summary


Day 2 Agenda – Casting Applications

• Foundry processes and castings evolution

• Casting alloys and designation system

• Foundry metallurgy essentials (101)

• Permanent mold and die casting alloys

• 356.2 series, 354, 355, 357, 359, 413


Day 2 Agenda – Casting Applications• High integrity aluminum structural die casting

o Conventional vs. high pressure vacuum die castings

o Case study

o Requirements and factors affecting thin wall structural casting

o Properties and tempers F-T4-T5-T6-T7

• Joining

• Modeling

• Stress-engineering strain curves


Day 2 Agenda – Corrosion and Repair• Introduction

• Objective

• Importance of aluminum surface technologies

• Impact of corrosion in automotive

• Surface influence on several automotive applications and in-service performances

• Factors determining rate of corrosion

• Typical forms of corrosion in automotive body sheets

• Sources of oxidation in aluminum processing

• Methods to control and improve surface quality of aluminum

• Influence of pretreatment on adhesive bonding in automotive joints

• Repair of aluminum panels and BIW parts


Aluminum Use in AutomobilesAluminum use is growing both in total

weight per vehicle and as a % of curb

weight

Includes all aluminum use (powertrain, BIW,

closures and suspension aluminum)


Common Uses of Aluminum

Suspension components

2019 Aluminum Transportation Group 12

BIW and Closures


Aluminum BIW and closure use increasing and as engines get smaller,

engine block/transmission weight is reduced.

BIW and Closures


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 OEM focus is on closure panels

• OEMs are developing future aluminum intensive body structures due to greater mass savings potential

• Secondary weight savings are reductions associated with subsystems driven by curb weight (for pass cars — often 25% of primary savings)

• The savings shown will result in a 10-14% curb weight reduction (for ICE vehicles)

Steel (1)

(kg)

Aluminum

(kg)

Typical Wt.

Saving (kg)

%

saving

Hood 16 8 8 50

Fenders 7 3.5 3.5 50

Deck lid 17 9 8 47

Doors 73 43 30 41

BIW 328 209 119 36

Total 441 272.5 168.5 44.870

50 kg

saved

Percentage of BIW + closure weight


Weight and Size History


Fuel Economy Regulations – Worldwide

Passenger Vehicle Fuel Economy Fleet Average Passenger Vehicle GHG Emissions Fleet

Average

20

30

40

50

60

70

80

2000 2005 2010 2015 2020 2025 2030

EU

Japan

South Korea

China

US

Solid Lines = Actual Std.

Dotted Lines = Estimated Std.

Conversion factor between fuel economy and CO2 emissions:

• 8887 g CO2 per gallon of gasoline

• 10180 g CO2 per gallon of diesel

MP

G (C

AF

E T

est C

ycle

Norm

aliz

ed)

70

90

110

130

150

170

190

210

230

250

270

2000 2005 2010 2015 2020 2025 2030

Solid Lines = Actual Std.

Dotted Lines = Estimated Std.

G-C

O2/k

m (N

ED

C T

est C

ycle

Norm

aliz

ed)

Regulations only get tougher moving forward


US 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!

20.0

25.0

30.0

35.0

40.0

45.0

50.0

55.0

60.0

65.0

35.0 40.0 45.0 50.0 55.0 60.0 65.0 70.0

T

a

r

g

e

t

M

P

G

Footprint (square feet)

CAFE Targets for Passenger Cars

2012 Car target

2016 Car target

2017 Car target

2018 Car target

2019 car target

2020 Car target

2025 Café Target

Chrysler 300MalibuCruzeFiesta


US CAFE – Light Truck Targets

What is a light truck?

20.0

25.0

30.0

35.0

40.0

45.0

50.0

55.0

30.0 40.0 50.0 60.0 70.0 80.0

T

a

r

g

e

t

m

p

g

Footprint (sq ft)

Truck CAFE targets

2012 Truck target

2016 truck target

2017 Truck target

2018 Truck Target

2019 truck target

2020 truck target

2025 truck target

F150DurangoGrand

Cherokee


0 1 2 3 4 5 6 7

Low Friction Lubricants

Engine Friction Reduction

VVT - Dual Cam Phasing (DCP)

Discrete Variable Valve Lift (DVVL) on OHV

Stoichiometric Gasoline Direct Injection (GDI)

Combustion Restart

Turbocharging and Downsizing

Exhaust Gas Recirculation (EGR) Boost

6/7/8-Speed Auto. Trans with Improved Internals

Dual Clutch or Automated Manual Transmission

Electric Power Steering

Improved Accessories

Belt mounted Integrated Starter Generator

Mass Reduction (1.5% of Curb Weight)

Mass Reduction (3.5 to 8.5% of Curb Weight)

Low Rolling Resistance Tires

Low Drag Brakes

Aero Drag Reduction

% Improvement in Fuel Economy

3.5 – 6%

Ref: Corporate Average Fuel Economy for MY2012-MY2016 Passenger Cars

and Light Trucks – Final Regulatory Impact Analysis, NHTSA, March 2010

14 – 25%

5.5 – 9.5%

Drivetrain Alone Cannot Provide the Fuel Savings Required by 2020


MP

G R

equirem

ents

Multi-material

High Volume Auto Body Evolution

Steel & Aluminum Hybrid(High scrap utilization, Steel to aluminum joining)

Tailoring Products

Aluminum Intensive Vehicle(Strength & ductility for safety, Robust joining)

Aluminum Closures(Increased formability for design/styling)

Evolution of auto design scenarios


Aluminum BIW are Not New

1922 Ford Model T


Grumman LLV

US Postal delivery trucks began production in 1987

Vehicle design life was 24 years and

was extended to 30 years in 2009


Acura NSX

All aluminum – 1990-2005 2016 – present


Audi Mixed-Material Vehicles

Audi A8

Aluminum since 1994

Audi TT

Aluminum since 2008 (hybrid steel/alum)Audi R8

Aluminum since 2006

Audi Q7 (hybrid steel/aluminum)

Aluminum since 2016


2016 Audi Q7 – Hybrid Steel/Aluminum

48% steel / 52% aluminum


Jaguar/Land Rover Aluminum VehiclesAll Jaguar and Land Rover vehicles have aluminum BIW

Jaguar XJ

Aluminum since 2003

Jaguar XE

Aluminum since 2015

Jaguar F-Type

Aluminum since 2013

Range Rover Sport

Aluminum since 1970, 2013

Jaguar F-Pace

Hybrid steel/aluminum

Jaguar XF

Aluminum since 2008


Range Rover


Range Rover

Product % of BIW

6xxx sheet 37%

5xxx sheet 37%

Extrusions 6%

Castings 15%

HS Steel 4%

PH Steel 1%


Ferrari/Lamborghini Aluminum Vehicles

Ferrari 430

Aluminum since 1998

Ferrari 599

Aluminum since 2003

Lamborghini Gallardo

Aluminum since 2003


Corvette Stingray

Aluminum since 2013

Z series aluminum since 2006


Tesla Model S Electric VehicleTesla Aluminum Vehicles – All Aluminum

Model S Model X

Model 3

Hybrid steel/aluminum BIW


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


Mercedes Benz C-Class (2014 to present)

24.8% aluminum


Mercedes Benz S-Class (2013 to present)

32% aluminum


All Aluminum Ford F-150 – Launched in 2015

Contributes to

CAFE improvement

for first time

America’s best-selling

vehicle for over 40 years

Best in class cargo

performance

700-890lbs lighter

than 2014 steel

model

2019 fuel economy (20/26 mpg) – 2WD 2.7 L Ecoboost (10 speed)

2019 fuel economy (22/30 mpg) – 2WD 3.0 L Diesel (10 speed)

Upgraded to five-star safety rating:

2014 Steel F150

2015 Aluminum F150


2014 Steel F-150 and 2015 Aluminum F-150 Comparison

Steel

2014 F150

(kg)

Aluminum

2015 F150

(kg)

Wt.

Savings

(kg)

% Savings

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

Cab 283 158 125 43

Cargo Box 105 60 45 43

Total 524 294 231 44

Reference: EuroCarBody 2015, October 21-22, 2015, Bad Nauheim, Germany.

•Ford F-Series is the best-selling

vehicle in America

•2015 F-150 is flagship vehicle

•Super Duty trucks (F-250, F-350,

F-450) also in aluminum

Supercrew with 5.5 ft box

Length = 5890 mm

Wheelbase = 3670 mm


Steel Ford F-150 and Aluminum F-150 Fuel Economy

37


Ford Super Duty, Expedition, Lincoln Navigator – All Aluminum


Cadillac CT6 – Hybrid Steel/Aluminum• 62% aluminum – 38% steel

Includes all aluminum closures


Chrysler Pacifica

Aluminum hood, sliding doors and liftgate (Mg cast inner)


2018 Jeep Wrangler

Aluminum hood and doors


2019 Silverado

Aluminum hood, doors and tailgate


RAM 1500

Aluminum hood and tailgate


Daimler Truck

Class 8 Cascadia cab

Aluminum since 1992

Business Class – M2 cab

Aluminum since 2001


Kenworth and Peterbilt Trucks

Class 8 Kenworth T680 Class 8 Peterbilt 579


Weight-Sensitive Trailers

Gasoline tankers

Dry bulk trailers


Weight-Sensitive Trailers

All aluminum flatbeds

Dry van and refrigerated trailers


Sustainability

Aluminum Is More Sustainable Today

Than Any Other Period In History

of all primary aluminum for automotive applications in North America is smelted in Quebec using

hydropower, resulting in the lowest production carbon footprint for the industry.

More than 75%

Most aluminum automotive parts also contain recycled aluminum, of which the energy demand and carbon footprint is just a tiny

fraction of primary aluminum. Combining these two factors, the production phase emissions of aluminum parts does not increase

when heavier counterparts are replaced. The significant reductions during a vehicle’s driving and end-of-life phases makes

aluminum stand out as the best material to reduce life cycle emissions.


Life Cycle Assessment

A literature review conducted by a team of US EPA researchers on 26 life cycle

assessment (LCA) studies concludes “most of the LCAs demonstrated that

aluminum-intensive designs were able to achieve the largest reductions in life-

cycle energy use and GHG impacts” (Source: Hottle et al 2017).

Several third-party North American LCA studies prove

aluminum’s ability to reduce life cycle energy demand and

GHG emissions of vehicles. Including recent studies

conducted by the Natural Resources Canada (Dubreuil et al

2012), Oak Ridge National Laboratory (Das 2014), Ford

Motor Company & Magna International (Bushi et al 2015)

and Athena Institute (Bushi 2018).


Life Cycle AssessmentReducing vehicle weight with aluminum

increases fuel economy while cutting

both tailpipe and life cycle emissions.

In 2019, the Automotive Science Group found the Ford F-150 holds the

smallest life-cycle carbon footprint of any full-size truck in North America.

The key…automotive aluminum. (Source: The Automotive Science Group)

An aluminum body on a pickup truck can

lower total life cycle global warming

potential and primary energy demand by

7.8 metric tons of CO2 equivalent.

(Source: 2018 EDAG Silverado Body

Lightweighting study)


Recycling

Aluminum can be recycled repeatedly. As a result,

these industry-leading automakers tap into an

endlessly renewable supply of aluminum through

their operations.

Jaguar Land Rover and Ford

Motor Company pioneered closed-

loop recycling of aluminum scrap in their

manufacturing efforts.

Ford’s F-150 manufacturing plants

recycle enough aluminum to produce

At the end of a vehicle’s life, automotive

aluminum is fully and appropriately

recycled and reused for

automotive parts. Two studies conducted by scientists at the

Worcester Polytechnic Institute showed that metal

recovery of automotive aluminum at the end-of-life

recycling is as high as 96% (Source: WPI 2016, 2018)

30,000 new trucks per month.(Source: Ford Motor Company)


Quiz

1. Open a browser on your laptop, tablet or mobile device

2. Visit: pollev.com/aassociation001

3. Answer the questions based on knowledge from this session.

https://pollev.com/aassociation001


Questions?

Aluminum Alloy Designations

The Aluminum Transportation Group


Aluminum Alloy Classifications

• Aluminum alloys are categorized by two main groups

• Wrought alloys are further divided into two subgroups

Casting Alloys Wrought Alloys

HEAT TREATABLE

ALLOYS

Their properties

depend on age

hardening

NON HEAT

TREATABLE

ALLOYS

Derive their

properties from

strain hardening

(work hardening)

HEAT TREATABLE

ALLOYS

Properties depend

on age hardening


Some Examples of Alloy-Temper Designations:

1050-O

3003-H24

6111-T4

5052-H32

7075-T6

What does it all mean?

Let’s deal with alloy first….

Alloy Temper


Aluminum Alloy Designation and Nomenclature

• The Aluminum Association system was adopted in 1954

xxxx

1. Alloy group

3. Modification of original

or impurity limits

2. Identification

of alloy, or

aluminum purity



1xxx at least 99.00% aluminum (Al)

2xxx main alloying element is copper (Cu)

3xxx main alloying element is manganese (Mn)

4xxx main alloying element is silicon (Si)

5xxx main alloying element is magnesium (Mg)

6xxx main alloying elements are magnesium AND silicon (Mg and Si)

7xxx main alloying element is zinc, Zn (usually also magnesium, Mg)

8xxx alloyed with other elements (e.g. Fe, Li)

xxxx

Non-heat treatable alloys

Heat-treatable alloys

The ‘catch all’ (mainly NHT, but some HT alloys also)

1. Alloy group



2. Identification or

aluminum purity

xxxx

For the 1xxx alloys (>99.00% Al) these

two digits tell you the purity of the alloy.

The digits are the minimum Al content

above 99%, examples:

1050 Al > 99.50%

1100 Al > 99.00%

1230 Al > 99.30%

For all the other alloys (non-1xxx) these

two digits identify the alloy within the main

alloy series, i.e. within 2xxx, or 3xxx, etc.

Generally arbitrarily assigned (although

some alloys inherited the 2-digit alloy

identifications existing prior to the

Aluminum Association system adopted in

1954 : 52S → 5052, 24S → 2024)



3. Modification of original

or impurity limits

xxxxThe first generation of the alloy is assigned the digit ‘0’

Example: 5083

The first modification of the alloy accepted by the Aluminum

Association as being a substantive variation of the base alloy is

assigned the digit ‘1’ Example: 5183

The next modification to the base alloy is assigned the digit ‘2’

and then the next again is assigned ‘3’ and so on: Examples:

5283, 5383, etc.

Note: If a variant of an alloy is not used for many years, it can

be discontinued, and removed from the ‘Teal Sheets’


Aluminum Association ‘Teal Sheets’


Why So Many Alloys?

• Aluminum Alloy Development

• Answer: “Suitability for use”• Strength

• Formability

• Corrosion resistance

• Toughness

• Etc…

• Pure/commercially pure aluminum (1xxx) has many attractive properties and is used in many applications, but we add elements (alloying) to enhance properties, especially strength

• Blending the mixture of added elements (‘alloying’) can furnish the optimum combination of properties for the application (further enhanced by processing)


AA Temper Definitions

1050-O

3003-H24

6111-T4

5052-H32

7075-T6

Temper


AA Temper Definitions

Heat Treatable Alloy: “T” - tempers

“An alloy which may be strengthened by a suitable thermal treatment” 2xxx, 6xxx, 7xxx are heat-treatable. Examples: 2024-T3, 6061-T6

Non-Heat Treatable Alloy: “H” - tempers“An alloy which can be strengthened only by

cold work” 1xxx, 3xxx, 5xxx, and some 8xxx are non-heat-treatable.

Examples: 3003-H19, 5052-H32


Basic Temper Designations

F As-Fabricated (e.g. as-hot rolled, as-cold rolled)

O Fully Annealed

Hxx Strain-Hardened(NHT wrought products only)

W Solution Heat-Treated (HT) and quenched (unstable)

Tx Thermal Treatment (HT)

F, O, and W are single digit temper designations, e.g.

6061-O, 7075-W, 3004-F

The H and T tempers have two or three further digits

(and sometimes more) to describe the temper


Aluminum Alloy Temper Nomenclature:

Non-Heat-Treatable AlloysMost of these temper designations are in the form:

Hxx

Strain hardened temper

Condition

1 = Strain hardened only

2 = Strain hardened and partial annealed

3 = Strain hardened and stabilized

4 = Strain hardened and lacquered or painted

Strength level

2 = Quarter hard

4 = Half hard

6 = Three quarters hard

8 = Full hard

9 = Extra hard


Heat Treat Temper Designations

F As-Fabricated

O AnnealedH Strain-Hardened

(wrought products only)

W Solution Heat-Treated and QuenchedT Thermal Treatment

(Excluding F, O, or H)


The ‘T’ Tempers• T1 cooled from an elevated temperature shaping process and naturally aged to a substantially

stable condition.

• T2 cooled from an elevated temperature shaping process, cold worked, and naturally aged to a substantially stable condition.

• T3 solution heat-treated, cold worked, and naturally aged to a substantially stable condition.

• T4 solution heat-treated and naturally aged to a substantially stable condition.

• T5 cooled from an elevated temperature shaping process and then artificially aged.

• T6 solution heat-treated and then artificially aged.

• T7 solution heat-treated and overaged/stabilized.

• T8 solution heat-treated, cold worked, and then artificially aged.

• T9 solution heat-treated, artificially aged, and then cold worked.

• T10 cooled from an elevated temperature shaping process, cold worked, and then artificially aged.

e.g. Tx51 Stress-relieved by stretchingOther digits may be added to signify additional processing:


OEM Specific Designations

• Most Auto OEMs purchase to one of their internal specifications

• For example: Ford

Ford

Spec

Typical Application AA Designation

6EH 6xxx outer panel with enhanced

hemming

6022, 6014

6DR1 6xxx exterior or interior 6022, 6016

6HS2 6xxx high strength 6111

6ST1 Alternative high strength 6061

5HF 5xxx High form 5182

5ST 5xxx standard 5754


OEM Specific Designations• Most Auto OEMs purchase to one of their internal specifications

• For example: GM

GM Spec Typical Application AA Designation

Al-S-6000-S-90 6xxx exterior panel 6022, 6014

Al-S-6000-IBR-100 6xxx exterior panel – improved paint bake 6022, 6016, 6451

Al-S-6000-IH-90 6xxx exterior enhanced hemming 6014, 6016, 6022

Al-S-6000-HS-115 Alternative high strength 6111

Al-S-6000-R-110-U 6xxx reinforcement 6022-T4, 6016-T4

Al-S-5000-S-110 5xxx High form 5182

Al-S-5000-RSS-100 5xxx High form – reduced stretcher strain 5182

Al-S-5000-ST-90-90 5xxx Standard 5754, 5454


Aluminum Design Manual

• The aluminum design manual has useful information for design

• It is not set up for automotive design and does not include the alloys we have been discussing, it includes:

• General bearing strengths,

• Methods of calculating design allowables

• Filler alloy selection guide

• Typical welded joint strengths

• Quick fatigue guides


AA Design Manual – Additional Property Information


AA Design Manual – Selection of Weld Filler Alloys


AA Design Manual – Local Buckling Allowables


Allowable Stresses


Minimum Bend Radii


To Convert from Steel to Aluminum:

To Match Bending Stiffness:• Since Modulus of aluminum is 1/3 of steel

Ialum = 3 Isteel

In most cases, the moment of inertia of aluminum parts can be roughly 2.5 Isteel.

When was the last time you upgauged a steel part to reach a stiffness requirement?

To Match Bending Strength:Salum sy alum = Ssteel sy steel

Salum = Ssteel (systeel/ sy alum)

• Density is 1/3, so significant weight savings are possible


X

Y

Ixx = (1/12)*((bd^3-b1d1^3))

Iyy = (1/12)*((db^3-d1b1^3))

dd1

b1

bA = bd – b1d1

Remember minor changes in section size can yield big gains


Simple Example

88

X

Y

d

b

X

Y

d

bSteel Aluminum

b = 60 mm

d = 40 mm

t = 2 mm

Ixx = 102272 mm4

Iyy = 193152 mm4

b = 60 mm (hold because of

packaging)

d = 50 mm (To increase stiffness –

target 2x)

t = 3 mm

Ixx = 241672 mm4 (2.36 x Steel)

Iyy = 322632 mm4 (1.67 x Steel)

Weight Savings = 45%


Rocker Example

89

Steel T=1.0 Aluminum T=2mm

168.3

89.3

Moments of Inertia Ixx = 2360195 mm4

Iyy = 668175 mm4

178.3

91.3Moments of Inertia Ixx = 5184127 mm4 (2.19 Ixx steel)Iyy = 1451793 mm4 (2.17 Ixx steel)Weight savings = 35%

Moments of Inertia (Centroidal)Ixx = 5826014 mm4 (2.47 Ixx steel)Iyy = 1835972 mm4 (2.75 Ixx steel)

Aluminum T=2.5mm


Roof Rail Example

90

Steel T=1.0 Aluminum T=1.5 mm

72.5

50

78.5

60Moments of Inertia (Centroidal)Ixx = 171111 mm4

Iyy = 90610 mm4 Moments of Inertia (Centroidal)Ixx = 327830 mm4 (1.92 Ixx steel)Iyy = 219817 mm4 (2.42 Iyy steel)Weight savings = 45%


Questions?


Tell Us How We Did!

1. Open a browser on your laptop, tablet or mobile device

2. Visit: pollev.com/aassociation001

3. Give us feedback!

https://pollev.com/aassociation001

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