Composite Aluminum Wire for Automotive Elastic Members
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Solution Overview
Problem
7000 series aluminum alloys used in elastic members have lower stress corrosion cracking resistance compared to 6000 series, necessitating a material with improved strength and stress corrosion cracking resistance for automotive applications.
Innovation Solution
A composite wire with a high-strength first alloy portion (tensile strength 950-1100 MPa) and a second alloy portion (tensile strength 100-650 MPa) is used, where the second alloy portion is layered over the first, with a thickness ratio of 0.01 to 0.2, providing enhanced stress corrosion cracking resistance and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If 7000 series aluminum alloy is used to increase tensile strength, then strength is improved, but stress corrosion cracking resistance deteriorates
Solution Approach 1:
The patent applies composite materials by creating a two-layer aluminum alloy structure where the first layer (950-1100 MPa tensile strength) provides high strength and the second layer (100-650 MPa tensile strength) provides stress corrosion cracking resistance. This composite structure resolves the contradiction by combining materials with complementary properties rather than using a single alloy that cannot simultaneously optimize both strength and corrosion resistance.
Solution Approach 2:
The patent applies local quality by differentiating the properties of different regions within the elastic member. The first alloy portion (core) has high tensile strength for structural support, while the second alloy portion (outer layer) has lower tensile strength but superior stress corrosion cracking resistance. Each region is optimized for its specific function, resolving the contradiction through spatial differentiation of material properties.
2Weight of moving object
If aluminum alloy is used instead of steel for weight reduction, then weight is reduced, but strength and stress corrosion cracking resistance need improvement
Solution Approach 1:
The patent uses composite aluminum alloy materials to achieve both weight reduction and improved strength/corrosion resistance. The two-layer structure combines lightweight aluminum alloy properties with optimized mechanical performance, maintaining the weight advantage of aluminum while overcoming its traditional strength limitations through the composite configuration.
Solution Approach 2:
The patent applies parameter changes by precisely controlling the tensile strength parameters of each layer (first layer: 950-1100 MPa, second layer: 100-650 MPa) and their thickness ratio (0.01-0.2). This parametric optimization enables the aluminum alloy elastic member to achieve strength levels comparable to or exceeding traditional materials while maintaining weight reduction benefits.
Data Source
AI summary
An elastic member is an elastic member formed of a wire having a cross section that is substantially circular, the cross section being orthogonal to a longitudinal direction, and the elastic member being expandable and contractible in a predetermined direction; and including: a first alloy portion that is made of an aluminum alloy having a tensile strength larger than 950 MPa and equal to or less than 1100 MPa at room temperature; and a second alloy portion configured to cover the first alloy portion, the second alloy portion having a thickness in a radial direction smaller than a radius of the first alloy portion, and being made of an aluminum alloy having a tensile strength of 100 MPa to 650 MPa at room temperature.