Aluminum Alloy Stamped Motor Vehicle Shell Component
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Solution Overview
Problem
The challenge lies in achieving a balance between formability and high mechanical strength in aluminum alloy components for automotive body structures, particularly in temper T4, while ensuring good riveting and crash-resistant behavior, along with resistance to corrosion and compatibility with assembly processes like spot welding and adhesive bonding, without increasing production costs.
Innovation Solution
A method involving the manufacturing of aluminum alloy components with a specific composition (Si: 0.60-0.85, Fe: 0.05-0.25, Cu: 0.05-0.30, Mn: 0.05-0.30, Mg: 0.50-1.00, Ti: 0.02-0.15, V: 0.00-0.15) that undergoes solution heat treatment, quenching, natural aging, artificial aging, and bake hardening to achieve enhanced mechanical properties and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum alloy sheets are used for structural parts with complex geometries, then weight reduction is achieved, but formability during stamping operations deteriorates
Solution Approach 1:
The patent applies parameter changes by controlling the temper of the aluminum alloy sheet (specifically T4 temper with controlled natural aging) to optimize the balance between formability and final strength. The solution involves adjusting the aging time and temperature parameters to achieve the desired formability during stamping while maintaining adequate mechanical properties in the finished component.
2Strength
If aluminum alloy sheets with high mechanical strength are used, then strength after service is improved, but formability in delivery temper deteriorates
Solution Approach 1:
The patent applies preliminary action by performing controlled natural aging of the aluminum alloy sheet in the T4 temper state before stamping operations. This preliminary aging treatment modifies the microstructure to improve formability during subsequent forming operations, while the final artificial aging treatment after stamping restores and enhances the mechanical strength of the formed component.
3Weight of moving object
If aluminum alloy sheets are used instead of steels for structural parts, then weight is reduced, but mechanical properties deteriorate
Solution Approach 1:
The patent resolves this contradiction by implementing a two-stage heat treatment process: controlled natural aging before stamping to optimize formability, and artificial aging after stamping to achieve the required mechanical strength (Rp0.2 ≥ 260 MPa). This parameter control approach enables aluminum alloy structural parts to simultaneously achieve weight reduction and adequate mechanical properties.
4Ease of manufacture
If aluminum alloy sheets with high formability are used, then stamping operations are improved, but mechanical strength after service deteriorates
Solution Approach 1:
The patent applies preliminary controlled natural aging treatment to the aluminum alloy sheet before stamping operations. This preliminary treatment maintains adequate formability for stamping while setting up the microstructure to respond appropriately to the subsequent artificial aging treatment, ensuring that the final component achieves the required mechanical strength (Rp0.2 ≥ 260 MPa) after service.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in components with a tensile yield strength of at least 260 MPa and a folding angle of at least 90°, offering improved formability, mechanical strength, and crash behavior, while maintaining resistance to corrosion and compatibility with various assembly processes.
Implementation Method 1
solution heat treatment, quenching, natural aging at room temperature, followed by hardening by artificial aging
Implementation Method 2
solution heat treatment, quenching, natural aging at room temperature
Implementation Method 3
natural aging at room temperature, followed by hardening by artificial aging
Implementation Method 4
hardening by artificial aging at a temperature of substantially 205° C. with a holding time of between 180 and 480 minutes
Implementation Method 5
bake hardening
Data Source
AI summary
The invention relates to a method for manufacturing a stamped motor vehicle bodywork or shell-structure component made of an aluminium alloy, comprising the steps of manufacturing a metal sheet or strip with a thickness of 0 to 3.5 mm made of an alloy with the following composition (wt %): Si: 0.60-0.85; Fe: 0.05-0.25; Cu: 0.05-0.30; Mn: 0.05-0.30; Mg: 0.50-0.00; Ti: 0.02-0.15; V: 0.00-0.15; other elements <0.05 each and <0.15 in total, remainder aluminium, with Mg<−2.67×Si+2.87, solution heat treating and quenching, pre-tempering, ageing for 72 hours to 6 months, stamping, tempering at a temperature of around 205° C. with a dwell time of 180 to 480 minutes or tempering at an equivalent time and temperature, painting and “bake hardening” at a temperature of 150 to 190° C. for 15 to 30 min. The invention also relates to a stamped motor vehicle bodywork or shell-structure component, further referred to as “body in white” produced by such a method.