res-1 asm eastern va, 2005-04-21 aluminum alloys for industrial applications - focus on ground...

ASM Eastern VA, 2005-04-21RES-1

Aluminum Alloys for Industrial Applications - Focus on Ground Transportation

Materials Selection for Applications Seminar

Eastern Virginia ASM2005 April 21

R. E. Sanders, Jr.Alcoa Technical CenterAlcoa Center, PA 15069


Outline

• Current aluminum applications– Automotive– Trucks, trailers, and tankers

• The case for aluminum– Payload and economics– Maintenance and appearance– Longer life– Safety and highway damage

• Materials development


United States and Canada

10,536 M tonnes (23.6 billion lbs)

Building &Construction

14.8%Exports10.1%

Other8.5%

Electrical6.4%

ConsumerDurables

6.8%

Containers& Packaging

21.3%

Transportation32.2% Ingot

33.4%

Extrusion & Tube16.5%

Other5.2%

Sheet, Plate& Foil44.8%

Aluminum Shipments by Major Market (2002 A. A. Statistical Review)

Major Market Product Form


2002 –Usage of Aluminum in North American Ground Transportation

Total: 2,950 M tonnes (6.6 billion lbs)

Trailers & Semis

492*

Trucks& Buses

767*

Passenger Cars5,348*

*values x 1 million pounds


Aluminum Alloys

•Wrought alloys – semi-fabricated– Available as sheet, plate, extrusions,

forgings– 8 major alloy systems: >400 alloys

•Cast alloys – net shape– 6 major alloy systems: >70 major

alloys

•How do you pick the alloy and product form?


The Alloy Selection “Puzzle”

• Properties and performance vary with product application• Strength may be a large or small piece of the puzzle• Optimizing one aspect of performance may cost us in

another area.

CorrosionResistance

Surface Quality Formability

Cost

JoiningStrength

FractureToughness

Finishing

Fatigue


About 95% of the Aluminum Alloys for Aerospace Applications Today Have Been Developed by Alcoa

30

40

50

60

70

80

90

100

1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010

Aerospace Alloys - Strength vs Year First Introduced

Upper Wing

Fuselage Skin

Lower Wing

Thick Product

Al-Li Alloys

Yie

ld S

tren

gth

, ks

i (T

yp

ica

l, L

-Dir

ecti

on

)

Year First Used in Aircraft or Aerospace

7075-T651B29

7178-T651707

7075-T7651L1011

7150-T651757/767

7150-T6151A310/MD11

7150-T7751C17

7055-T77777

2324-T39737

2324-T39 Type II777

2017-T4Junkers F13

Wings, Fuselage, Others(Alcoa)

2024-T3DC3

Wings, Fuselage, Others

2524-T3777

7075-T7351DC10

7050-T7451A62020 Wing Plate

RA5C Vigilante

2090-T83 Thin PlateAtlas/Centaur Payload Adapter

2097 Thick PlateF16 Bulkhead

2195-T8M4 Thin PlateExt Fuel Tank of Space Shuttle

A6013-T6A318

C433-T351A340-500/600

2026-T3511A340-500/600

7055-T795XA380

7085-T7X5XA380

2017-T4Junker F13

Wings, Fuselage, Others

7055-T765XA380

A340-500/600A380A318


2xxx Alloy Aerospace Applications

Alloy 2519 Armor Plate

Space Shuttle Fuel TanksAlloy 2219, Alloy 2195

Alloys 2x24 Sheet Aircraft

From ATC Slide LibraryFuselage Under Construction -- alloy 2024


High-Strength 7xxx Alloys

Alloys 7050/7055 Sports Equipment Alloys 7150/7055 Extrusions

Alloys 7150, 7085 Aircraft (Upper Wings) Alloys 7175/7050/7085 Forgings


Aluminum vs. Steel in Automobiles– Steel was used in Europe and USA for outside of

vehicles before 1903– Complex body frames in early 1900s – Al castings – “All-Steel” car body invented and patented in 1912

(Edward G. Budd)– Aluminum preferred for auto body panels before 1920

(i.e., ductility)– First large sheet metal presses (stamping) gave steel

edge after 1920– Renewed interest in Aluminum in 1970s following

energy crisis and CAFÉ legislation– Current steel usage in autos still > 50% of vehicle

weight– Aluminum usage is currently 130 kg per vehicle


Cast Aluminum Bodies - 1904

Alcoa Builds Aluminum Auto Bodies for the Ford Model T in New Kensington, PA.


Aluminum in Trucking Applications

•By 1930’s aluminum was recognized as key weight saving material for trucks– Delivery vehicles– Dump trucks– Tankers

2000 extra liters per load

1800 extra kg. per load


Al Body Delivery Truck – circa 1936

Weight savings vs. steel – 500 kg25 extra cases of drink per load; payback in 140 trips


Automotive Applications

Wheels

ClosurePanels

TransmissionBrackets

Wiring Harness

Heat ExchangerComponents/Radiators

SuspensionComponents

Drive Shaft Yokes

BumperBeams

Knuckles and Control Arms

AirbagCanisters

Fasteners, Stamping Assemblies

EngineComponents

Steering Yokes

BrakePistons/Calipers

ElectronicComponentsBody-in-white

Structure

Step Plates

Inner Door Panels

Cross members

Water PumpHousings

WindshieldSurrounds

Full Frames

Examples of Aluminum Utility & Flexibility


Product Selection

• Aluminum sheet– Forming critical parts– Flat surfaces– Design for dent resistance and stiffness

• Extrusions– Longitudinal stiffeners– Energy Absorption– Ease of assembly

• Castings– Part simplicity, low cost

• Forgings– High performance finished parts, e.g., wheels


6xxx Alloy Auto Sheet Applications

Nissan Altima

Ford RangerChrysler LHS

2002 Harley-Davidson


Al space frames use extrusions as energy absorbing structure

Audi A8

Ferrari Modena


Alloy 6061 Forged Wheels

• Heavy Duty Truck Wheels• Motorcycle Wheels• Crane Wheels• Automotive\SUV\Light

Truck


Roof sheetRoof sheet

Side sheetSide sheet

Extrusions forExtrusions forskeleton, side postsskeleton, side posts

Floor, Floor, scuff plate, scuff plate, tread platetread plate WheelsWheels

HuckHuckfastenersfasteners

North American Commercial Vehicles

The Utility Logo is a Registered Trademark of Utility Trailer Manufacturing Co.

Cab doorsCab doors

Fuel tanksFuel tanks

Body trimBody trim

Frame Frame

railsrails

Cross Cross membersmembers

Cab structureCab structure

Huck Chassis

fasteners

Huck Chassis

fasteners

Wiring harnessWiring harness WheelsWheels

Huck Cab fastenersHuck Cab fasteners

Peterbilt is a Registered Trademark

BumperBumper


Advantages of Aluminum

• Light weighting saves 500-800 kg per trailer vs steel– Increased payload (payback is very short) (next slide)– Marginal fuel savings (493 liters/160,000 km)– Better braking and improved safety (lower center of gravity)– Less damage to roads from overloaded trucks– Longer tire life for dump trailers: $400/year for 8-tire trailer

• Lower corrosion-related maintenance costs– No need to paint flat beds or dump trucks

Cost to re-paint steel vehicles every five years: $600

– No rust when sheet is sheared or scratched– Better appearance over time, easy to clean

• Premium attractive appearance– Bright trim, bumpers, fuel tanks, tread plate

• Non-sparking


Economics• Payload-limited tractor trailers can increase

productivity by increasing payload– The tare weight of heavy vehicles is limited to

36,363 kg (80,000 lbs) in US

• Consider: – Incremental cost of Aluminum vs steel (~$3000)

– Increased payload revenue results in payback in 0.5 to 2.0 years depending upon mileage


Highway Safety and Road DamageChina – 2001-2002

• Many truck accidents caused by overloading• 119 deaths in Beijing alone, caused by

overloaded trucks in 2001-2002• Overloading causes failure of safety critical

components: Tires; brakes; wheels; axles• Such failures are usually catastrophic.

• Rmb 4 billion in Hebei province was spent in 2001 alone for road damage repairs.

• Lightweighting with Al can reduce tendency to overload, improving safety and highway life.


Road Damage from Overloaded Trucks


Material Selection for Truck Parts

Use Alloy Key AttributesChassis, Trailer Frames

6061-T6 extrusion Strength, fatigue*

Side Sheets 3004, 5052-H291 Painted, durability

Roof 3003-H1x Wide width

Fuel Tanks 5052-O Impact resistance*

Compressed Air 5083, 5754, 5154 Impact resistance*

Wheels 6061-T6 Fatigue, surface, wear

Cab Sheets 6022, 6111-T4, 5182-O Formability

Bumpers 6061, 5xxx Surface, strength

Trim Various 3xxx, 5xxx Good surface

* After welding


Dry Van Wall Product Attributes

• Alloy 3004 or 5052-H291 Side Sheets– Hard temper for high strength and dent resistance– Painted surface for corrosion durability– Economical to produce– Available in wide range of colors, surfaces, and finishes

• Alloy 6061-T6 Extrusions– Moderate strength, good fatigue– Shapes facilitate truck frame manufacture and assembly– Economical to produce

• Alloy 6061 or 5xxx for Bumpers– High strength for dent resistance– Bright, durable finish after polishing

• Alloy 3003-H1x Sheet for Roofs– Moderate strength, Wide width to eliminate seams


Aluminum Tanker Trucks


Aluminum in Tanker trucks

• Aluminum tankers used to haul petrol for US armed forces in World War II

• Alcoa marketed aluminum tanker trucks for commercial use starting in late 1940’s

• Alloy 5454 introduced in early 1950’s to insure good corrosion performance in tanker applications

• Aluminum tankers currently carry oil, petrol (gasoline), chemicals, cement, and other dense materials

• Currently alloy 5083 (Europe) and 5454 (USA) are most commonly used alloys

• Non-sparking nature of aluminum improves safety in crash situation


Economics: Aluminum Tankers

• Practically all aluminum tanker trucks are limited by total weight (not by volume)

• Lightweighting with Aluminum can haul more volume at same weight – or – haul equal volume at lower weight - typically 10% higher payload for same or less operating cost vs steel design

• Value of Aluminum is in reduced number of loads to haul same amount of cargo


Alloy Selection for Tankers

• Alloy 5454 (2.7 Mg, 0.6 Mn) – H321 temper– Good combination of strength and formability– Excellent corrosion resistance, even after elevated

temperature exposure– Good weldability– Good fatigue resistance after welding

• Available as Bulk Transport Sheet (BTS) in various finishes– Mill finish – Consistent uniform surface finish– Specular – Engineered bright finish– Al Bright – ultimate in brightness and image clarity

• Alloys 5083 and 5182 – standard alloys used in Europe


Future Directions

• Improved alloys for automotive applications– Better formability for sheet– Castings which do not require heat

treatment (lower cost)– Extrusions for energy absorption

•Couple alloy, process development and design


Filiform Corrosion(3 weeks Exposure to Dry Bottom MASTMAASIS per ASTM G85)


Summary and Conclusions

• Economics drives aluminum usage– More payload: Lightweighting with Al pays for itself quickly

in weight-limited applications– Reduced maintenance costs due to corrosion

• Additional benefits: attractive appearance, safety, reduced damage to highways and infrastructure

• Proper selection of Al alloys enables maximum benefits to be realized– High strength where needed– High formability (sheet)– High fatigue performance (forgings)– Parts simplification (extrusions and castings)

• Development of new materials is proceeding in combination with design technology


Acknowledgements

• Alcoa Technical Center– Shawn Murtha– Ron McClure– Andy Trageser– Greg Bartley– Jotpreet Chahal

• Alcoa Asia-Pacific– Michael Swain– Anil Govada

res-1 asm eastern va, 2005-04-21 aluminum alloys for industrial applications - focus on ground...

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