Aluminum R and D for Automotive uses and the Department of Energy's Role

摘要

Although aluminum has achieved tremendous growth in the automotive market over the past decade, it has largely been in the specific areas of engine components, transmissions, wheels, and heat exchangers. Further growth is dependent on an increasing penetration into the engine block market and new structural components such as the BIW and closure panels. The cost of engine blocks is hampered by the need for and cost of cylinder liners. The cost of aluminum auto body sheet is still in the $1.30 range or higher, 30% above the $1/lb that is regarded as the price for aluminum to be widely used. This is also higher than the $1.10 to $1.20 that new tailor welded blanking technologies may be economic. Forming and joining technologies are needed for aluminum to be more widely used in the BIW structure, and high-volume designs that utilize aluminum's strengths would improve penetration. Research involving lower-cost processes or alloys must continue before aluminum can further penetrate these markets. DOE-funded research is important to these areas, and it satisfies the needs of the industry. The currently funded DOE research seems to have the right mix of cast and wrought aluminum projects. Several projects concentrate on the development of databases and predictive models to enhance the application of aluminum in automotive applications. Significant advances have been made in the rapid prototyping of cast aluminum parts and forming of wrought aluminum parts. Further work is needed in the validation of tools developed by means of demonstration in actual automotive parts.