Light material
The high-length and light expansion materials used on the body are mainly in high length steel and ultra-fortune steel, aluminum alloy, engineering plastics in magnesium and online alloy with materials.
High resistance steel
High resistance steel is mainly used in key parts such as A, B, C -Pillaire, threshold beams, door threshold beams, collision beams at the door and roof beams, and develop gradually due to the proportion of public. The proportion of high intensity steels in the body in Europe and the United States exceeded 60%, such as Audi A3, BMW 3 Series, Cadillac Ats, Ford Mondeo, etc.; %, like Infiniti Q50, Honda Civic, etc.;
Aluminum alloy
The aluminum alloy gradually extended from the engine blanket to the wing board, to the blanket of the luggage compartment and the door.
Magnesium alloy
The magnesium alloy has developed from the steering wheel skeleton, from the skeleton of the seat to the support support and the shell parts based on the transmission;
Composite fiber improvement material
Improved fiber -improved composite materials began to be applied to components such as the front module, the rear door and the intake collectors; As the figure shows, a car with a body structure with four notes.
Structure optimization design
In terms of structural optimization design, at the start of the development of the model, it is more important to make the body structure more reasonable. Currently, the light design of the structure of the multi-material body is currently faced with the construction of a configured design platform (photo). Development of integrated optimization design management.
1. Equipment application
1. Steel with high lengthHigh intensity steel is mainly used in the interior and outdoor board and the structure of the car. Advanced rigidity has just been applied to the ultra-light steel body of the car and the advanced concept car. Although challenges such as rebounds are faced with rebounds in molding, compared to other alternative materials, steel with high length is always the best cost and most attractive material.2. Aluminum alloyThe aluminum alloy application began in the 1990s, represented by the complete spatial framework of aluminum launched by Audi Motors. The concept of Audi all-aluminum bodywork (ASF) has been proposed, and the corresponding Audi100 body, the first generation of Audi A8, A2. , Xinluhu Range Rover, Mercedes -Benz S -Class Car and so on illustrated in the figure.
The transformed aluminum alloys developed more quickly in the application of structures at the body level, such as the aluminum alloy baggage cover more and more widely developed, the cover of the engine cabin, the rear door, The bumper beam, etc. With solidified aluminum alloy, in powdered metallurgical aluminum the development and development and application of alloying, ultra-plastic aluminum alloy, aluminum-based composite materials and aluminum materials in widen foam will further in The scope of the aluminum alloy in the automotive automobile application in the future, and will present the form of coexistence of casts, profiles, and plates.
Audi A8 all the aluminum body
3. Magnesium alloy
Currently, the magnesium alloy is mainly concentrated on the steering wheel skeleton on the body. On the components of the skeleton of the dashboard, the seat skeleton, there are no mass production applications on the structure of the white body. Currently, only the Klezler model has tried it, as shown in the figure. Due to the restrictions on corrosion resistance and the molding of the magnesium alloy, it has not yet been widely used.
4. Composite materials
The technology of composite materials in the automotive industry is first applied to the bumper, then the spring steel plate section is replaced by the section of the section of the section, then the four blocks and two blocks are used with production. The large -scale application of composite materials was after the mid -1980s. In 1990, Ford and Chrysler successively developed composite materials.
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With the development of composite technology of composite materials, it is now widely used in sports cars and luxury cars. Variety of automobile components of form structures, such as the application of BMW i3 Electric Vehicle composite material.
2. Manufacturing process
1. Hot trainingHigh precision and good training performance are widely used in the production of high intensity car bumpers, door-collision rods, improved parts in C-Pillaire, roof frames, medium canals and other safety parts and structural parts. Currently, technology is growing quickly abroad. The lower part of the body of the red H7 red flag also uses a large -scale heat sage technology, as shown in the figure:
2. Laser welding
In 1985, Audi managed to adopt the first laser welding board in the world. In the 1990s, large automotive companies in Europe and the United States and Japan began using large-scale laser welding technology. In recent years, this technology has been widely used in the design and global manufacturers of the steel body. As the FAW H7 body shows, a structural part typical of using laser welding.
The use of laser welding technology can reduce the number of automotive parts, reduce body weight, increase the rate of use of raw materials, improve structural function and increase product design flexibility.
3, poor plan
Once the laser was welded, it seems to solve the problem of the existence of laser tiles.
The poor thick plate can replace the laser welded plate to better reach a light weight. However, it is not completely replaced by laser welding cards, as laser welding can also weld different materials and plates of resistance to weld in addition to welding different thick plates.
Third, estimate of costs
Compared to other light quality materials, steel at high length is at low price and a good savings can improve vehicles. Steel at high length can reduce the material, so the higher cost compared to ordinary steel plates cannot increase significantly, about 1.5 times that of ordinary steel plates.
The density of the aluminum alloy is 2.68 g / cc, only 1/3 of the steel plate. Since the use of aluminum materials must increase thickness and transverse section, it can lose weight from 30% to 50%.
The density of the composite carbon fiber material is 1.5 g / cc, which is not as good as 1/5 of the steel. Composite carbon fiber materials can be applied to the door, to cover the engine compartment and luggage covers can lose weight by more than 50%, and their material costs have increased by more than 5 times compared to Steel plates.
Fourth, light level
The mild automobile industry has not formed in scale, the industrial chain is not complete and the gap with abroad is important. The high length steel body represents more than 60% of traditional international models, and steel with 780MPA resistance level and 980MPA is quite common on body components. Steel with high length can lose weight from 20 to 30% without lowering safety and comfort.
Certain parts of the foreign or domestic dimensions are applied to light materials. Components of composite carbon fiber components can be reduced by 40% ~ 60% of the components of steel components.
Fifth, light technical path of the body
The light path of the foreign body is illustrated in the figure below:
Move foreign technologies can explore the development path for the light technological development of my country
1. In the short term
Objectives: Increase the proportion of rigidity steel and ultra-fortune steel, reasonably reduce the thickness of the thin steel plate and largely use advanced training technology and bonding technology to reach the light target expected .
Way: adopt steel with high length, ultra-fortune steel, engineering plastics, the appropriate quantity of magnesium aluminum alloy and composite materials to optimize the parameters of the body structure. , Thermal training technology and advanced application connection technology.
2. Middle
Objectives: Master the characteristics of the aluminum-magnet alloy, characteristics of composite materials and connection technology. country.
Way: expand the application report and the number of components on the body of the aluminum-magnet alloy and composite materials. The material itself.
3. Long -term
Objective: gradually master the characteristics of carbon fiber composite materials, component design methods, effective manufacturing technology, performance control methods and connection technology, and gradually catch up with the level of light automobile technology in developed countries in the automotive industry.
Way: Interestingly applying the technology of design, manufacturing and connection of the hybrid body in steel and aluminum, and gradually enter the design of the structure of components of composite carbon fiber materials. Effective manufacturing, performance regulation and connection technology, widen the application ratio of composite carbon fiber materials in cars.
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