Elevated Temperature Forming of 7000-series Aluminum Automotive Structural Components

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The proposed research will address the efficient fabrication of automotive components using 7000-series aluminum sheet alloys to reduce automobile weight. These alloys offer tremendous weight reduction potential due to their high specific strength compared to conventional steels; however, their limited room temperature formability makes it difficult to manufacture required complex shapes. This proposal outlines a two-year Phase II project that follows a successful three-year Phase I project completed in December, 2017. Phase II will comprise: (i) further development and exploitation of optimized warm forming and die quenching processing routes (identified in Phase I as being potentially highly efficient, fast fabrication strategies); (ii) development of non-isothermal precipitation hardening models; (iii) studies of die coatings/lubricants and manufacturing "runnability"; (iv) development of enhanced process and performance models; and, (v) further studies of corrosion performance focused on the processing routes under investigation. This new phase will see continued study of the baseline AA7075 alloy investigated in Phase I, as well as limited studies on AA6013. An additional alloy, AA7050, will be introduced which exhibits low quench sensitivity and is targeted for future automotive application. The process/performance models and data, coupled with important manufacturability characterization of the alloys, coating and lubricant systems under investigation, will be delivered to our industry partners, Honda, Magna (Promatek Research Centre) and Arconic. The final outcome of this research will be commercial processing routes to fabricate high strength, light weight automotive structural components for rapid commercialization by our industry partners. Benefit to Canada, beyond commercial application, will be accrued through improved vehicle performance by structural lightweighting, leading to reduced fuel consumption and lower greenhouse gas emissions.