Page 177 - Manufacturing Engineering and Technology - Kalpakjian, Serope : Schmid, Steven R.

|56 Chapter 6 Nonferrous Metals and Alloys: Production, General Properties, and Applications

EXAMPLE 6.| An All-aluminum Automobile
Aluminum use in automobiles and in light trucks has refined, the structural frame design had to be
been increasing steadily. As recently as 1990, there optimized, and new tooling designs (to allow forming
were no aluminum-structured passenger cars in pro- of aluminum) had to be developed. Because of these
duction anywhere in the world, but in 1997 there new technologies, the desired environmental savings
were seven, including the Plymouth Prowler and the were able to be realized without an accompanying
Audi A8 (Fig. 6.2). With weight savings of up to 47% drop in performance or safety. In fact, the Audi A8 is
over steel vehicles, such cars use less fuel, create less the first luxury-class car to earn a dual five-star
pollution, and are recyclable. (highest safety) rating for both driver and front-seat
New alloys and new design and manufacturing passenger in the National Highway Transportation
methodologies had to be developed. For example, Safety Administration (NHSTA) New Car Assessment
welding and adhesive bonding procedures had to be Program.

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Fiobotically applied, advanced arc-welding processes
provide consistent high-quality assembly of castings,
extrusions, and sheet components

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Advanced extrusion bending processes
support complex shapes and tight radii
(bi
FIGURE 6.2 ia) The Audi A8 automobile, which has an all-aluminum body structure. (b) The aluminum body structure,
showing various components made by extrusion, sheet forming, and casting processes. Source: Courtesy of ALCOA, Inc.