Abstract
The new concept for design and manufacturing of lightweight load-bearing components for the automotive industry has been presented. According to this concept the stiffness of the component can be enhanced using aluminum foam prepared by powder metallurgical (PM) techniques. This extremely lightweight material offers the variety of realistic applications especially for shaped structural panels or for stiffening of complex hollow parts. Partial foaming of hydroformed or hollow welded profile will improve the properties in weakest sections of the profile, which allows to design its overall thickness according to a mean and not a peak stress. This approach increases the property-to-weight ratio of the component. These elements seem to be also very efficient energy absorbers in crushable zones of vehicles and have to manage the collision energy for the rigid passenger cell protection, reducing also the deceleration during the impact. Beside stiffening and increasing energy absorbing capabilities the reduction of noise and vibrations is also expected. Development of technological methods for the preparation of lightweight load-bearing automotive components using aluminum foam is under intensive research. The aim of the investigation is the reduction of weight, costs and improvement the properties of parts via optimization of the manufacturing process.