Extruded aluminium profiles for use in car making - new solutions for improved lightweight construction

摘要

Ever-increasing demands resulting from the development of new vehicle generations have initiated both for the development of modern constructional materials as well as for the competition between them. Lightweight construction is particularly important in the car industry because today the expressed demand for reduced fuel consumption, and thus above all weight reduction, is more pressing than ever. Here, the latest legislation from the European Union, which lays down fixed limits for vehicle emissions to reduce CO_2 emissions, and penalty taxes if these limits are exceeded, presents a complete new challenge for lightweight construction. It also opens up new opportunities,rnhowever, for the materials used. Otto Fuchs KG based in Meinerzhagen, Germany, has been committed to the development and processing of lightweight materials by forging and extrusion since the 1930s. Today, more than ever before, the company is making important contributions to the further development of aluminium alloys and extruded components in this intensely competitive environment. There was particular focus in recent years on four projects with different demands or objectives: an alloy with tensile strength of up to 500 MPa coupled with high corrosion resistance; an alloy with the highest possible tensile strength, up to 700 MPa; an alloy with crash capability and tensile strength classes of up to 305 MPa; and complex multi-chamber profiles with tensile strengths greater than 330 MPa and damage-tolerant properties. The alloys and the manufacturing of the profiles, which places high demands on the layout and control of the process, are described in detail below. The improved and unique properties of the profiles are described together with their practical capabilities.