Firstly, introduction of aluminium used in modern automobile manufacturing.

The automobile manufacturing industry has become the most important large consumer of aluminum materials. more than 12%~15% of the world’s aluminum consumption is used in the automobile industry, and some developed countries have exceeded 25%. 2002, the whole European automobile industry consumed more than 1.5 million t of aluminum alloy in one year, of which about 250,000 t were used in the manufacture of body, 800,000 t were used in the manufacture of automobile driveline, and another 42.8 million t were used in the manufacture of automobile driving mechanism and suspension mechanism.

Secondly, the type of aluminium used in different parts of the car.

Types of aluminium used in different parts of the car. 6000 series is suitable for the front bonnet of the car and the car wheel hub, 5000 series is suitable for some plasticity better parts, such as 5083 series is suitable for super plastic deformation of aluminium on the car body, 5754 is suitable for continuous casting, the car chassis adopts 5083 aluminium alloy, 5754 aluminium alloy, 6061 aluminium alloy and so on. The four doors and two covers of the car are mainly made of 5182 aluminium.

Process requirements for aluminium alloy stamping plates in stamping

The forming process of aluminium alloy is the same as that of plain cold plate, and it is possible to reduce the use of scrap knives and the generation of aluminium chips by increasing the number of processes, but there are differences between its mould requirements and those of plain cold plate.

Aluminium alloy pressed sheet metal parts in welding process requirements

The main processes used in the welding of aluminium alloy bodies are resistance welding, CMT cold transition welding, tungsten arc welding, riveting, punching and polishing.

Rivetless joining process for aluminium alloy plates

Rivetless connection of aluminium plates is a process of cold extruding 2 or more layers of metal plates by means of pressure equipment and special moulds, and then forming an internal inlaid joint with a certain tensile and shear strength. The thickness of the connected plates can be the same or different, there can be adhesive layer or other intermediate layer, and the material can be the same or different. The connection effect is good, without the need for auxiliary connectors.

Punching and riveting process for aluminium alloy parts

Punch rivet connection of aluminium sheet parts is to use punch riveting equipment to press the punch rivets into the connected material to form a stable, secure and beautiful connection point.

Resistance welding

the resistance welding of aluminium alloy is generally used in the medium frequency or high frequency resistance welding process, the welding process is only in the welding tongs electrode diameter size range, and in a very short period of time to melt the base metal and the formation of a molten pool, welded joints quickly cooled to form a connection, resulting in the possibility of aluminium and magnesium dust is extremely small. Most of the welding fume produced is oxide particles of metal surface and surface impurities. Welding process are equipped with workplace local exhaust, can be timely these particles through the air blower discharged into the atmosphere, basically does not produce aluminium and magnesium dust deposition.

CMT Cold Transition Welding and Argon Arc Welding

These 2 welding processes, due to the protection of inactive gas, at high temperatures, the contact between its molten metal and oxygen is not sufficient, under the action of the arc’s jet, it can produce aluminium and magnesium metal particles of small granularity, and splash to the working environment, forming aluminium and magnesium dust deposition, there is a danger of aluminium and magnesium dust explosion, and it is necessary to do the work of preventing and treating the dust explosion.

Process requirements for aluminium stamped sheet metal parts on rolled edges

(1) Aluminium alloy roll edge pressing and cold plate roll edge pressing is very different, the toughness of aluminium is not as good as steel, the pressing force can not be too large, the pressing speed is relatively slow, generally 200 ~ 250 mm/s, each pressing angle can not be greater than 30 °, can not be V-shaped pressing;

(2) Aluminium alloy pressing temperature requirements: at 20 ℃ room temperature, just retrieved from the cold storage parts should not be immediately rolled edge pressing.

Aluminium alloy stamping plate washed passivation drying process

(1) The temperature of the parts from room temperature to 140 ℃ for about 7 min, the shortest time of gel hardening is 20 min.

(2) Aluminium parts from room temperature to the insulation temperature of about 10 min, aluminium insulation time of about 20 min, aluminium parts from the insulation temperature to the temperature of the parts 100 ℃ cooling time of about 7 min, after the end of the insulation, cooled to room temperature, so that the whole of the aluminium parts of the drying process for 37 min.

In summary

the details of the various processes of aluminium alloy stamping plate parts in the automotive process manufacturing are introduced. Aluminium alloy sheet has unparalleled advantages over other lightweight materials in terms of cost, manufacturing technology, mechanical properties, sustainability, etc. Therefore, aluminium alloy will become the lightweight material of choice in the automotive industry.

About Delin Aluminum

Delin Aluminum, a brand of AOYIN METALS, specializes in marine-grade aluminum plates with DNV, ABS, BV, and CCS certifications. We supply 5083, 5086, and 5052 aluminum sheets and plates for shipbuilding and offshore applications worldwide. Learn more about us →