Abstract
The specific characteristics of aluminium alloys offer the possibility to design lightweight structural components and modules with high stiffness and excellent crash energy absorption potential. The wide range of aluminium product forms, e.g. sheets, tubes, extruded profiles as well as net-shaped parts produced by different techniques which are available in different alloys, sizes and geometries of various degrees of complexity allow the cost efficient production of structural components for small and large series. Key to a successful introduction of aluminium structural modules into the automotive market is a total systems approach taking into account all the benefits offered by the material, the applicable component production processes and the use of aluminium-oriented manufacturing and surface finishing processes.
The paper will focus on a demonstration of the advantages which can be achieved by an integrated design and engineering approach using in particular sheet stampings, intricately shaped extruded sections and large, high quality thin-walled die castings. The examples will include bumper systems, instrument panel supports as well as car body structure modules. Intimate knowledge of the material characteristics including crash behaviour enables rapid product development based on computer aided design and engineering methods. Numerical simulation of the related fabrication processes ensures the efficient production of the structural modules in a high consistent quality.