What is objective of reading this blog?
Before going to start
this blog, we must understand why we need to study this blog?
Let us think .......why?
In order to reduce the
consumption of energy and also for avoiding the air pollution, requirement of
more fuel efficient automobile or vehicles are in demand and it is big
challenge for automobile industries.
There are various unique
characteristic of aluminum for example
- Excellent formability properties
- Higher strength & stiffness in respect of weight-
ratio
- Properties of recyclability
- Good resistance against corrosion and this is very important property of this material
We must be note down
that these properties of aluminium propose it the best and ideal aspirant for
replacing the heavy materials such as copper and steel in car and other luxury
vehicles for full filling the requirement of automobile industries of weight reduction.
In this Blog we will discuss the recent development in application of aluminum alloy in casting, metal forming and extrusion process for automobile industries.
In this Blog we will discuss the recent development in application of aluminum alloy in casting, metal forming and extrusion process for automobile industries.
We will consider two
examples also where we will see that how automobile industries started to apply
aluminium for better efficiency of vehicles in fuel consumption and
environmental impact or air pollution point of view.
In first example we will
discuss hang on parts produced by Hoogovens Rolled Products Duffel and must be
noted that the potential of weight could be approximate 50%.
In current situation,
5000 alloys are preferred because they are of high degree of formable and
applied normally for inner panel, whilst heat treatable 6000 alloys are applied
for the application of outer panel.
In this blog we will review of recent progress or development in alloy of aluminium for amending the formability as well as surface quality in both type of alloy i.e. 6000 and 5000 aluminium alloy and also the discussion on response of brake hardening of 6000 alloy.Further we will discuss the recycling of aluminium alloys scraps.
In this blog we will review of recent progress or development in alloy of aluminium for amending the formability as well as surface quality in both type of alloy i.e. 6000 and 5000 aluminium alloy and also the discussion on response of brake hardening of 6000 alloy.Further we will discuss the recycling of aluminium alloys scraps.
The second example that
we will take is brazing sheet. From more than last 10 years there were nice
trend of increasing for replacing the copper- heat exchangers with other one
produced from brazed aluminium.
With the help of above
mentioned two examples, we will come to know about the technical as well as commercial
aspects of the aluminium automobile components production processes and
engineering design & support of materials resources will also be in
consideration.
Introduction
The competition of
material in the sector of automobile industries has been conventional
comprehensive. Even since 1920s, Steel was the best suited material on the
basis of its application for example application of steel in building
construction and automobile also.
The increase in requirement for amending the economy of fuel triggered by concerns regarding global warming as well as requirement of energy is also very important factor during the selection of materials.
The increase in requirement for amending the economy of fuel triggered by concerns regarding global warming as well as requirement of energy is also very important factor during the selection of materials.
Let us consider one
example of US government policy for automobile industries, US government has
decided that automobile industries have to reduce the exhaust emission of
vehicle, amend the safety of occupant as well as also help in the growth of
fuel economy.
In order to meet the requirement as stated above, automobile industries are completely involved to amend the efficiency of conventional engine, to reduce the overall weight of vehicle.
The reduction in weight is very important because as we know that the average weight of vehicle will be increased as in these days every automobile industry representing new model of vehicle with lot of facility of luxury, performance, convenience and safety also as safety is required by customers.
In order to meet the requirement as stated above, automobile industries are completely involved to amend the efficiency of conventional engine, to reduce the overall weight of vehicle.
The reduction in weight is very important because as we know that the average weight of vehicle will be increased as in these days every automobile industry representing new model of vehicle with lot of facility of luxury, performance, convenience and safety also as safety is required by customers.
There is various safety
facilities for example anti block systems, enhancing safety body- structure and
air bag and must be noted that these safety devices also contributing in weight
of vehicle.
Although, we have
observed that automobile industries especially car manufacturer have taken this
seriously and have changed some design for optimum efficiency.
Automobile industries that by only changing some design or modification, there will not be any significant reduction in weight. Later it was realized that if light weight materials will be used then only we may achieve them according to rule of thumb 10% reduction in weight approximately will be equal to a 5.5% amendment in the fuel economy.
Reduction in weight is a very important factor and it was determined that 10% in weight of automobile or vehicle reduction take place which will results in 8–10% of fuel economy.
Automobile industries that by only changing some design or modification, there will not be any significant reduction in weight. Later it was realized that if light weight materials will be used then only we may achieve them according to rule of thumb 10% reduction in weight approximately will be equal to a 5.5% amendment in the fuel economy.
Reduction in weight is a very important factor and it was determined that 10% in weight of automobile or vehicle reduction take place which will results in 8–10% of fuel economy.
It was concluded that
materials for components of automobile can have an important impact on the
environment and it was also decided to use materials of lighter weight for
producing the components.
The application of materials of lighter weight will help us for reducing weight of vehicle and hence improve economy of fuel. The target of weight reduction has driven a slowly decrements in the quantity of cast iron and steel utilized in vehicles and the respective increment in the quantity of other various alternative materials such as plastics and aluminium.
We have tried to explain by displaying following Figure. In this blog we will only focus on opportunities of aluminium alloys in automobile industries.
The application of materials of lighter weight will help us for reducing weight of vehicle and hence improve economy of fuel. The target of weight reduction has driven a slowly decrements in the quantity of cast iron and steel utilized in vehicles and the respective increment in the quantity of other various alternative materials such as plastics and aluminium.
We have tried to explain by displaying following Figure. In this blog we will only focus on opportunities of aluminium alloys in automobile industries.
The changes in consumption of material in an average car
Aluminum Alloy for application in automobile industries
Application of Aluminum in automobile industries for automotive uses has been increased approximate more than eighty percent in last five years. There was very strong anticipation of application of aluminum in trunk lids, hoods as well as for doors in hanging position on a frame of steel.
Development
in consumption of aluminum for automotive areas in Europe
We may see in above
figure the Development in consumption of aluminum for automotive application in
Europe
As we may observe in
above figure that a significant increment in the sheet of aluminum for
application of automotive uses is normal or expected and we will also consider
this in detail.
We may observe the application of aluminum in automobile industries for various uses such as chassis, cover-power trains, structure of body and system of air conditioning. Casting of aluminum metal has been in consideration and in application for creating various types of automobile components since so many years.
We may observe the application of aluminum in automobile industries for various uses such as chassis, cover-power trains, structure of body and system of air conditioning. Casting of aluminum metal has been in consideration and in application for creating various types of automobile components since so many years.
It is observed by
automobile industries during the manufacturing of engine block, engine block is
main part of engine, the switching to aluminum material from cast iron and when
they have developed the engine block from aluminum, a quite reduction in weight
is observed.
It is demand of aluminum that we have seen in the application of it in modern car as engine block of aluminum increased by 50 % by the year of 2000.
It is demand of aluminum that we have seen in the application of it in modern car as engine block of aluminum increased by 50 % by the year of 2000.
We may see in above
figure about the demand of casting of aluminum in the sector of automobile. In
case of automotive - power train, casting of aluminum have been utilized for approximate 100%
for pistons, approximate 75% for cylinder heads and approximate 85% for
intake manifolds as well as for transmission such as rear axle, drive shaft and
various types of housings etc.
Let us discuss for the
application of aluminum in chassis, casting of aluminum are normally
utilized for approximate 40% for wheels and casting of aluminum are also be
used for components of brake , brackets, suspension system, components of
steering such as air bag supports, knuckles , steering shafts, wheels and housings.
Wrough aluminum and aluminum alloys are more in demand as compared to casting of aluminum. Wheels are normally forged to meet the requirement of more extreme loading conditions with better mechanical characteristics are required.
Wrough aluminum and aluminum alloys are more in demand as compared to casting of aluminum. Wheels are normally forged to meet the requirement of more extreme loading conditions with better mechanical characteristics are required.
We have observed a lot
of application of wrought aluminum such as applications in case of heat shields,
air bag housing, bumper reinforcements, pneumatic systems, seat frames, sumps
and side impact panels etc. Aluminum alloys are also utilized extremely in case
of heat exchangers.
Up to 1970, in sector of
automobile it was normally observed that heaters and radiators were made by
brass and copper with the help of soldered joints. During the crisis of oil in
the year of 1974, triggered were designed in order to form the structure of
lighter weight and to meet this aluminum metal were used.
Audi AL2 with Aluminum frame body
Aluminum
extruded frame shape
Let us consider some
important aluminum alloy those are commonly used in automobile sectors.
- AlSi6Cu4- AlSi9Cu3
- AlSi9Mg
- AlSi17Cu4Mg
- AlSi7Mg
- AlSi7MgMn
- AlSi11MgSr
- AlSi12(18)Cu Ni Mg
- AlSi25Fe3Ni2
Environmental Impact
Let us discuss about the
environmental impact of using aluminium during the production of designed
components.
Overall, the complete
procedure of transforming raw material such as bauxite into the aluminum is
very energy intensive process, needed resources of water,
electricity for producing and this is only basic reason that why power plants
were made completely for supporting the aluminium industries.
As all we know that the
ore of pure aluminum is so stable and will required lot of electrical energy
for yielding of the final product and must be noted that around half portion of
the energy of smelting in the U.S. will be consumed in courtesy of coal.
We must be aware that one of the most famous and notable source for polluting fuel sources known to mankind.
We must be aware that one of the most famous and notable source for polluting fuel sources known to mankind.
According to the EPA,
The releasing phenomenon of perfluorocarbons during the process of smelting of
aluminum and must be aware that approximate 9,200 times more harmful as
compared to the negative role of carbon dioxide in global warming.
During the extraction of
bauxite, the strip mining procedure will remove all native vegetation in the
sector of mining area, and therefore it will be loss for local people in terms
of food and snacks as well as significant soil erosion.
Emissions of Greenhouse
gas, released in the process of smelting & processing consisting,
perfluorocarbons,carbon dioxide, polycyclic,sodium fluoride, sulfur dioxide
aromatic hydrocarbon and also a list of other problematic elements.
Particulates those are
used to release during the process that are considered as to
compromise with the quality of air that consist combustion by-products,
limestone caustic aerosols, charred lime ,dust from bauxite, sodium salt and
alumina.
We may analyze at the
alumina unit, and we will come to know that the hazardous emission such as dust
of bauxite from handling & processing, dust of limestone from limestone
handling unit, dust of burnt lime from bins and conveyors, dust of
alumina from materials handling unit, dust of red mud dust & sodium salts
from red mud stacks.
Life cycle of analysis of Aluminium
Life cycle analysis means the study of application of aluminium in automobile industry from initial stage to final stage and again recycling of material. In general we may see how recycling and life cycle analysis is carried out in automobile industries.
Let us consider how process takes place
Life cycle analysis of Aluminum
provides quite benefits via process of recycling and must be noted that we may
save 95% of energy of energy that it would require to create new aluminum
metal. Approximate two –third all aluminum metals are recycled and use again
and again.
There are basically five
stages for recycling of aluminum metal as mentioned below
- Collecting scrap
- Sorting scrap
- Crushing
- Remelting
- Casting
Conclusion
After discussing and
analyzing above essay we have concluded some advantage and some disadvantage
also as listed below.
Advantage
With the application of
aluminium in automobile sector the main advantage of using aluminium is its
lighter density or weight. In current technology every automobile sector has
wish to reduce the overall weight and to increase the efficient utilization of
fuel.
Aluminium has more resistance against corrosion as compared to steel , but this benefit is only for consumer because selling of cars will be less as car will be rusty lesser than car made of steel.
Disadvantage
- Aluminium is slightly more expensive
- Aluminium is not suitable for welding
- Aluminium is not feasible for painting
- Sheet of aluminium is very difficult for stamping with car body
We will go ahead with
next blog i.e " Hydraulic fluid " now .
Let us move towards next
post............
Hydraulic
Keep Reading.......
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