Although the use of aluminum in cars has been increasing for the past two decades (from 39 kg (3 %) in 1976 to 89 kg (7 %) in the mid-nineties), progress has been limited in developing aluminum auto bodies. In fact, most aluminum substitution has come in the form of castings and forgings in the transmission, wheels, et cetera. Car manufacturers have developed aluminum cars with two competing designs: conventional unibody and the space frame. However, aluminum is far from being a material of choice for auto bodies. The substitution of aluminum for steel is partly influenced by regulatory pressures to meet fuel efficiency standards by reducing vehicle weight, and to meet recycling standards. The key obstacles are the high cost of primary aluminum as compared to steel (aluminum by weight is about five times more expensive than steel) and added fabrication costs of aluminum panels (most of the costs are the machine and laser-head costs). Both the aluminum and the automotive industries have attempted to make aluminum a cost-effective alternative to steel. This paper analyzes the cost of fabrication and assembly of four different aluminum car body designs in two classes (small, fuel-efficient vehicles and mid-size vehicles), making comparisons with conventional steel designs at current aluminum prices and using current aluminum fabrication technology. It then attempts to determine if aluminum can be an alternative to steel at lower primary aluminum prices (about USD 2.2 per kg), and improved fabrication processes.
Automobile bodies: Can aluminum be an economical alternative to steel?
Ist Aluminium im Fahrzeugbau eine ökonomische Alternative zu Stahl?
JOM - The Journal of the Minerals, Metals and Materials Society ; 53 , 8 ; 28-32
2001
5 Seiten, 14 Bilder, 3 Tabellen, 10 Quellen
Aufsatz (Zeitschrift)
Englisch
Repairs to steel and aluminum automobile bodies
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