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

该项目将解决设计和优化，材料选择和纹理开发，以及制造 一种一体式挤压前栏杆，旨在为雪佛兰Malibu等中型汽车批量生产， 2017年后的雪佛兰黑斑羚和别克帝王。除了整体式前导轨，其他结果包括：完整的 最大限度地提高能量吸收特性的前轨设计优化和一种新的铝合金，不仅 非常适合挤压，但表现出卓越的能量吸收和强度特性。 这项提议围绕三个高度整合的主题构建：(1)优化重量减轻和 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，以实现最大的性能和重量 还原。这将通过增加单位质量的能量吸收来实现(以改善性能)和 缩短前轨长度(减轻重量)。前导轨长度小于O.Bm，总重量减轻 30%-40%(在前轨；与钢材相比)是目标。 合金开发：基于Pilot合金AA6063的性能，将开发一种强度高的铝合金 以及可与传统钢材媲美的能量吸收特性。一旦开发出来，就会有几种测试，比如 如拉伸、弯曲、压缩、穹顶、双向应力测试，以及使用电子技术进行的微观结构研究 显微镜将被用来表征所开发的合金的机械和物理性能。 简化的制造流程：挤压比具有多个部件的复杂组件更具成本效益 冲压，将被用来制造新的钢轨。 最终，这个项目将解决设计和优化，材料选择和纹理开发，以及 制造一体式挤压前栏杆，用于中型汽车的大规模生产，如 2017年后的雪佛兰Malibu、雪佛兰黑斑羚和别克帝王。除了一体式前导轨，其他结果 包括：完整的前轨设计优化，最大限度地提高能量吸收特性和新的铝制 这种合金不仅非常适合挤压，而且表现出优异的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.