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Aluminum Alloys for Industrial Applications - Focus on Ground Transportation

Aluminum Alloys for Industrial Applications - Focus on Ground Transportation. Materials Selection for Applications Seminar Eastern Virginia ASM 2005 April 21. R. E. Sanders, Jr. Alcoa Technical Center Alcoa Center, PA 15069. Outline. Current aluminum applications Automotive

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Aluminum Alloys for Industrial Applications - Focus on Ground Transportation

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  1. Aluminum Alloys for Industrial Applications- Focus on Ground Transportation Materials Selection for Applications Seminar Eastern Virginia ASM 2005 April 21 R. E. Sanders, Jr. Alcoa Technical Center Alcoa Center, PA 15069 ASM Eastern VA, 2005-04-21

  2. Outline • Current aluminum applications • Automotive • Trucks, trailers, and tankers • The case for aluminum • Payload and economics • Maintenance and appearance • Longer life • Safety and highway damage • Materials development ASM Eastern VA, 2005-04-21

  3. Sheet, Plate& Foil 44.8% Ingot 33.4% Extrusion & Tube 16.5% Other 5.2% Aluminum Shipments by Major Market (2002 A. A. Statistical Review) United States and Canada Major Market Product Form Building & Construction 14.8% Transportation 32.2% Exports 10.1% Other 8.5% Electrical 6.4% Containers & Packaging 21.3% Consumer Durables 6.8% 10,536 M tonnes (23.6 billion lbs) ASM Eastern VA, 2005-04-21

  4. Trailers & Semis492* Trucks& Buses 767* Passenger Cars5,348* 2002 –Usage of Aluminum in North American Ground Transportation Total: 2,950 M tonnes (6.6 billion lbs) *values x 1 million pounds ASM Eastern VA, 2005-04-21

  5. Aluminum Alloys • Wrought alloys – semi-fabricated • Available as sheet, plate, extrusions, forgings • 8 major alloy systems: >400 alloys • Cast alloys – net shape • 6 major alloy systems: >70 major alloys • How do you pick the alloy and product form? ASM Eastern VA, 2005-04-21

  6. The Alloy Selection “Puzzle” • Properties and performance vary with product application • Strength may be a large or small piece of the puzzle • Optimizing one aspect of performance may cost us in another area. ASM Eastern VA, 2005-04-21

  7. About 95% of the Aluminum Alloys for Aerospace Applications Today Have Been Developed by Alcoa A340-500/600 A380 A318 ASM Eastern VA, 2005-04-21

  8. 2xxx Alloy Aerospace Applications From ATC Slide Library Fuselage Under Construction -- alloy 2024 Alloys 2x24 Sheet Aircraft Space Shuttle Fuel Tanks Alloy 2219, Alloy 2195 Alloy 2519 Armor Plate ASM Eastern VA, 2005-04-21

  9. High-Strength 7xxx Alloys Alloys 7150, 7085 Aircraft (Upper Wings) Alloys 7175/7050/7085 Forgings Alloys 7050/7055 Sports Equipment Alloys 7150/7055 Extrusions ASM Eastern VA, 2005-04-21

  10. Aluminum vs. Steel in Automobiles • Steel was used in Europe and USA for outside of vehicles before 1903 • Complex body frames in early 1900s – Al castings • “All-Steel” car body invented and patented in 1912 (Edward G. Budd) • Aluminum preferred for auto body panels before 1920 (i.e., ductility) • First large sheet metal presses (stamping) gave steel edge after 1920 • Renewed interest in Aluminum in 1970s following energy crisis and CAFÉ legislation • Current steel usage in autos still > 50% of vehicle weight • Aluminum usage is currently 130 kg per vehicle ASM Eastern VA, 2005-04-21

  11. Cast Aluminum Bodies - 1904 Alcoa Builds Aluminum Auto Bodies for the Ford Model T in New Kensington, PA. ASM Eastern VA, 2005-04-21

  12. Aluminum in Trucking Applications • By 1930’s aluminum was recognized as key weight saving material for trucks • Delivery vehicles • Dump trucks • Tankers 1800 extra kg. per load 2000 extra liters per load ASM Eastern VA, 2005-04-21

  13. Al Body Delivery Truck – circa 1936 Weight savings vs. steel – 500 kg 25 extra cases of drink per load; payback in 140 trips ASM Eastern VA, 2005-04-21

  14. Automotive Applications WindshieldSurrounds Electronic Components Wiring Harness Body-in-white Structure Airbag Canisters Fasteners, Stamping Assemblies Water PumpHousings Steering Yokes Closure Panels Brake Pistons/Calipers Bumper Beams Wheels Suspension Components Step Plates Heat Exchanger Components/Radiators Drive Shaft Yokes Cross members Inner Door Panels Transmission Brackets Knuckles and Control Arms Engine Components Full Frames Examples of Aluminum Utility & Flexibility ASM Eastern VA, 2005-04-21

  15. Product Selection • Aluminum sheet • Forming critical parts • Flat surfaces • Design for dent resistance and stiffness • Extrusions • Longitudinal stiffeners • Energy Absorption • Ease of assembly • Castings • Part simplicity, low cost • Forgings • High performance finished parts, e.g., wheels ASM Eastern VA, 2005-04-21

  16. 6xxx Alloy Auto Sheet Applications Ford Ranger Chrysler LHS Nissan Altima 2002 Harley-Davidson ASM Eastern VA, 2005-04-21

  17. Audi A8 Ferrari Modena Al space frames use extrusions as energy absorbing structure ASM Eastern VA, 2005-04-21

  18. Alloy 6061 Forged Wheels • Heavy Duty Truck Wheels • Motorcycle Wheels • Crane Wheels • Automotive\SUV\Light Truck ASM Eastern VA, 2005-04-21

  19. North American Commercial Vehicles Extrusions for skeleton, side posts Roof sheet Huck Cab fasteners Cab doors Cab structure Side sheet Body trim Huck Chassis fasteners Cross members Frame rails Floor, scuff plate, tread plate Wheels Fuel tanks Huck fasteners Bumper Wiring harness Wheels Peterbilt is a Registered Trademark The Utility Logo is a Registered Trademark of Utility Trailer Manufacturing Co. ASM Eastern VA, 2005-04-21

  20. Advantages of Aluminum • Light weighting saves 500-800 kg per trailer vs steel • Increased payload (payback is very short) (next slide) • Marginal fuel savings (493 liters/160,000 km) • Better braking and improved safety (lower center of gravity) • Less damage to roads from overloaded trucks • Longer tire life for dump trailers: $400/year for 8-tire trailer • Lower corrosion-related maintenance costs • No need to paint flat beds or dump trucks • Cost to re-paint steel vehicles every five years: $600 • No rust when sheet is sheared or scratched • Better appearance over time, easy to clean • Premium attractive appearance • Bright trim, bumpers, fuel tanks, tread plate • Non-sparking ASM Eastern VA, 2005-04-21

  21. Economics • Payload-limited tractor trailers can increase productivity by increasing payload • The tare weight of heavy vehicles is limited to 36,363 kg (80,000 lbs) in US • Consider: • Incremental cost of Aluminum vs steel (~$3000) • Increased payload revenue results in payback in 0.5 to 2.0 years depending upon mileage ASM Eastern VA, 2005-04-21

  22. Highway Safety and Road DamageChina – 2001-2002 • Many truck accidents caused by overloading • 119 deaths in Beijing alone, caused by overloaded trucks in 2001-2002 • Overloading causes failure of safety critical components: Tires; brakes; wheels; axles • Such failures are usually catastrophic. • Rmb 4 billion in Hebei province was spent in 2001 alone for road damage repairs. • Lightweighting with Al can reduce tendency to overload, improving safety and highway life. ASM Eastern VA, 2005-04-21

  23. Road Damage from Overloaded Trucks ASM Eastern VA, 2005-04-21

  24. Material Selection for Truck Parts ASM Eastern VA, 2005-04-21 * After welding

  25. Dry Van Wall Product Attributes • Alloy 3004 or 5052-H291 Side Sheets • Hard temper for high strength and dent resistance • Painted surface for corrosion durability • Economical to produce • Available in wide range of colors, surfaces, and finishes • Alloy 6061-T6 Extrusions • Moderate strength, good fatigue • Shapes facilitate truck frame manufacture and assembly • Economical to produce • Alloy 6061 or 5xxx for Bumpers • High strength for dent resistance • Bright, durable finish after polishing • Alloy 3003-H1x Sheet for Roofs • Moderate strength, Wide width to eliminate seams ASM Eastern VA, 2005-04-21

  26. Aluminum Tanker Trucks ASM Eastern VA, 2005-04-21

  27. Aluminum in Tanker trucks • Aluminum tankers used to haul petrol for US armed forces in World War II • Alcoa marketed aluminum tanker trucks for commercial use starting in late 1940’s • Alloy 5454 introduced in early 1950’s to insure good corrosion performance in tanker applications • Aluminum tankers currently carry oil, petrol (gasoline), chemicals, cement, and other dense materials • Currently alloy 5083 (Europe) and 5454 (USA) are most commonly used alloys • Non-sparking nature of aluminum improves safety in crash situation ASM Eastern VA, 2005-04-21

  28. Economics: Aluminum Tankers • Practically all aluminum tanker trucks are limited by total weight (not by volume) • Lightweighting with Aluminum can haul more volume at same weight – or – haul equal volume at lower weight - typically 10% higher payload for same or less operating cost vs steel design • Value of Aluminum is in reduced number of loads to haul same amount of cargo ASM Eastern VA, 2005-04-21

  29. Alloy Selection for Tankers • Alloy 5454 (2.7 Mg, 0.6 Mn) – H321 temper • Good combination of strength and formability • Excellent corrosion resistance, even after elevated temperature exposure • Good weldability • Good fatigue resistance after welding • Available as Bulk Transport Sheet (BTS) in various finishes • Mill finish – Consistent uniform surface finish • Specular – Engineered bright finish • Al Bright – ultimate in brightness and image clarity • Alloys 5083 and 5182 – standard alloys used in Europe ASM Eastern VA, 2005-04-21

  30. Future Directions • Improved alloys for automotive applications • Better formability for sheet • Castings which do not require heat treatment (lower cost) • Extrusions for energy absorption • Couple alloy, process development and design ASM Eastern VA, 2005-04-21

  31. Filiform Corrosion(3 weeks Exposure to Dry Bottom MASTMAASIS per ASTM G85) ASM Eastern VA, 2005-04-21

  32. Summary and Conclusions • Economics drives aluminum usage • More payload: Lightweighting with Al pays for itself quickly in weight-limited applications • Reduced maintenance costs due to corrosion • Additional benefits: attractive appearance, safety, reduced damage to highways and infrastructure • Proper selection of Al alloys enables maximum benefits to be realized • High strength where needed • High formability (sheet) • High fatigue performance (forgings) • Parts simplification (extrusions and castings) • Development of new materials is proceeding in combination with design technology ASM Eastern VA, 2005-04-21

  33. Acknowledgements • Alcoa Technical Center • Shawn Murtha • Ron McClure • Andy Trageser • Greg Bartley • Jotpreet Chahal • Alcoa Asia-Pacific • Michael Swain • Anil Govada ASM Eastern VA, 2005-04-21

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