Sustainable lightweighting technologies: High strength high crush efficiency extruded aluminum front rails for lightweight bodies

该项目将解决的设计和优化，材料选择和纹理的发展，和制造 一种用于在中型汽车，例如雪佛兰Malibu， 2017年之后的雪佛兰Impala和别克君威。除了一体式前轨，其他成果包括： 前轨设计优化，最大限度地提高了能量吸收特性，并采用了新型铝合金，不仅 非常适合挤出，但表现出优越的上级能量吸收和强度特性。 该提案围绕三个高度集成的主题构建：（1）前导轨设计，以优化重量减轻， 性能，（2）铝合金开发和（3）简化制造工艺开发。 优化的前轨设计：前轨几何形状和材料将进行优化，以实现最大性能和重量 还原这将通过增加每单位质量的能量吸收来实现（以提高性能）， 缩短前轨的长度（减轻重量）。前轨长度小于0.Bm，总重量减轻 30-40%（在前导轨中;与钢相比）是目标。 合金开发：基于“中试”合金AA 6063的特性，将开发一种具有强度 以及与传统钢相当的能量吸收特性。一旦开发出来，几个测试，如 如拉伸、弯曲、压缩、圆顶、双轴应力测试，以及使用电子显微镜的显微结构研究。 将进行显微镜检查以表征所开发的合金的机械和物理性质。 简化的制造工艺：挤出，比具有多个组件的复杂组件更具成本效益 冲压件，将用于制造新的轨道。 最终，该项目将解决设计和优化，材料选择和纹理开发， 制造用于中型汽车内大规模生产的单件式挤压前纵梁，例如 2017年之后的雪佛兰Malibu、雪佛兰Impala和别克君威。除了一体式前轨外， 包括：一个完整的前轨设计优化，最大限度地提高能量吸收特性和一个新的铝 这种合金不仅非常适合挤压，而且还表现出优越的上级能量吸收和强度特性。

This project will address the design and optimization, material selection and texture development, and manufacturing of a one-piece extruded front rail intended for mass production within mid-size cars, such as the Chevrolet Malibu, Chevrolet Impala and Buick Regal after 2017. Apart from the one-piece front rail, other outcomes include: a complete front rail design optimization that maximizes energy absorption characteristics and a new aluminum alloy that is not only perfect for extrusion, but demonstrates superior energy absorption and strength characteristics. This proposal is built around three highly integrated themes: (1) front rail design for optimized weight reduction and performance, (2) aluminum alloy development, and (3) simplified manufacturing process development. Optimized front rail design: The front rail geometry and material will be optimized for maximum performance and weight reduction. This will be achieved by increasing the energy absorption per unit mass (to improve performance) and shortening the length (weight reduction) of the front rail. Front rail lengths of less than O.Bm and a total weight reduction of 30-40% (in the front rail; compared to steel) are targeted. Alloy development: Based on the properties of 'pilot' alloy AA6063, an aluminum alloy will be developed with strength and energy absorption characteristics that are comparable to conventional steels. Once developed, several tests, such as tension, bending, compression, dome, biaxial stress tests, as well as microstructural studies using electron microscopy will be performed to characterize mechanical and physical properties of the developed alloy. Simplified manufacturing process: Extrusions, which are much more cost efficient than complex assemblies with multiple stampings, will be used to fabricate the new rails. Ultimately, this project will address the design and optimization, material selection and texture development, and manufacturing of a one-piece extruded front rail intended for mass production within mid-size cars, such as the Chevrolet Malibu, Chevrolet Impala and Buick Regal after 2017. Apart from the one-piece front rail, other outcomes include: a complete front rail design optimization that maximizes energy absorption characteristics and a new aluminum alloy that is not only perfect for extrusion, but demonstrates superior energy absorption and strength characteristics.