Materials for Automobile Bodies, Second Edition

The selection of automobile body materials is fundamental to the choice of fabrication method, and the characteristics and performance of the final vehicle or component. The factors behind these choices comprise some of the key technological and design issues facing automotive engineers today. Materials for Automobile Bodies brings together a wealth of information on automotive materials and material technologies to provide designers and vehicle body engineers with both a solid grounding and a quick reference to inform their material choices. Coverage includes materials processing, formability, welding and joining, anti-corrosion technologies, plus a comprehensive consideration of the implications of materials selection on these processes. Dealing with the whole assembly process from raw material to production, right through to recycling at the end of a vehicle's life, this book is the essential resource for practising engineers, designers, analysts and students involved in the design and specification of motor vehicle bodies and components. Up-to-date detailed information on contemporary autobody materials, incorporating the explanation often lacking in other data-focused resources Includes informative and insightful case studies on the materials and processing choices of major OEMs, including Honda, BMW and Audi Now with more on geographical supply and usage trends, environmental concerns and end of life disassembly considerations, and how these affect selection choices Front Matter......Page 1 Table of Contents......Page 3 1.1 Introduction......Page 9 1.2 Overview of Content......Page 11 1.3 Materials Overview......Page 12 1.4 General Format of Presentation......Page 18 1.5 Introduction to Body Architecture and Terminology......Page 21 References......Page 23 2. Design and Material Utilization......Page 25 2.1 Introduction......Page 26 2.2 Historical Perspective and Evolving Materials Technology......Page 27 2.2.3 Early Materials and Subsequent Changes......Page 28 2.3.1 Materials for Autobodies......Page 36 2.4.2 Structural Dynamics......Page 41 2.4.3 Design for Static Stiffness......Page 42 2.4.4 Crashworthiness......Page 43 2.4.5 Weight Efficiency......Page 44 2.5 Panel Dent Resistance and Stiffness Testing......Page 50 2.6 Fatigue......Page 52 2.6.1 Designing against Fatigue......Page 54 2.7.1.1 The Honda NSX......Page 56 2.7.2 The Pressed Spaceframe or Base Unit Concept - Steel......Page 57 2.7.3 Pressed Aluminum Spaceframes and Associated Designs......Page 61 2.7.4.1 Audi A8 and A2......Page 64 2.7.5.1 Hybrid Designs in Aluminum and Steel......Page 70 2.7.5.2 Hybrid Designs with Composites......Page 71 2.7.6 Designs Based on Carbon Fiber or CFRP......Page 72 2.7.6.1 The Influence of Alternative Drive Systems......Page 76 2.8.1 General......Page 82 2.8.2.1 Tube Hydroforming......Page 83 2.8.2.3 Sandwich Materials......Page 88 2.9 Engineering Requirements for Plastic and Composite Components......Page 92 2.10 Cost Analysis......Page 93 References......Page 98 3. Materials for Consideration and Use in Automotive Body Structures......Page 100 3.1 Introduction......Page 101 3.2 Material Candidates and Selection Criteria......Page 105 3.2.1 Consistency: A Prime Requirement......Page 107 3.3 Steel......Page 108 3.3.1.1 Vacuum Degassing......Page 110 3.3.1.3 Hot- and Cold-Rolling Processes......Page 111 3.3.1.4 Continuous Annealing......Page 115 3.3.1.5 Skin Passing......Page 117 3.3.2 Surface Topography......Page 118 3.3.4 Higher Strength Steels......Page 124 3.3.4.1 Ultra High-Strength Steels......Page 125 3.3.4.3 Stainless Steel......Page 132 3.4.1 Production Process......Page 135 3.4.2 Alloys for Use in Body Structures......Page 136 3.5 Magnesium......Page 139 3.6.2 Thermoplastics......Page 140 3.6.3 Thermosets......Page 141 3.6.4.2 Glass-Mat Thermoplastic Compression Molding......Page 142 3.6.5 Advanced Composites for Competition Cars......Page 144 3.7 Repair......Page 146 Learning Points......Page 149 References......Page 150 4. The Role of Demonstration, Concept and Competition Cars......Page 151 4.1 Introduction......Page 152 4.2 The ECV 3 and ASVT......Page 153 4.3.1 ULSAB and ULSAB 40......Page 159 4.3.2 FreedomCAR Program......Page 161 4.3.3.1 Overview Report......Page 163 4.3.3.2 Phase 2 Report......Page 165 4.3.4 SuperLIGHT-CAR Project......Page 167 4.4 Concept Cars......Page 168 4.5.1 Introduction......Page 177 4.5.3 History......Page 179 4.5.5 Duty - The Survival Cell Structure......Page 180 4.5.6 Rule Conformity and Weight......Page 181 4.5.8 F1 - A Good Match for Composites......Page 183 4.5.9 Design......Page 184 4.5.10 Chassis Loading......Page 185 4.5.11 Analysis......Page 186 4.5.12 Materials Database......Page 187 4.5.15 Survival Cell Crush and Penetration......Page 188 4.5.16 Survival Cell Impact......Page 189 4.5.17 Impact Absorber Design......Page 190 4.5.20 Materials......Page 191 4.6 Rally Cars......Page 192 4.7 Hypercars......Page 193 Learning Points......Page 195 References......Page 196 5. Component Manufacture......Page 198 5.1.1 Sheet Metal Pressworking......Page 199 5.1.2.1 Parameters Derived in the Uni-Axial Tensile Test......Page 203 5.1.2.2 Forming Limit Diagrams......Page 206 5.1.2.3 Modeling of the Sheet Forming Process......Page 207 5.1.3 Effect of Surface Topography......Page 208 5.1.5 Tooling Materials......Page 210 5.1.5.2 Cutting Materials......Page 211 5.1.6.1 Tube Hydroforming......Page 213 5.1.6.2 Sheet Hydroforming......Page 219 5.2 Aluminum Formability......Page 220 5.2.1.1 Material Selection......Page 221 5.2.1.2 Product and Process Design......Page 224 5.2.1.3 Trimming Operation......Page 227 5.2.1.4 Flanging and Hemming......Page 228 5.2.1.5 Paint Process Implications for Aluminum......Page 229 5.2.2 Superplastic Forming......Page 230 5.3 Manufacture of Components in Magnesium......Page 233 5.4 Production of Polymer Parts......Page 236 5.4.1 CFRP for EV and the Future......Page 238 Learning Points......Page 242 References......Page 243 Content......Page 245 6.2.1 Resistance Welding......Page 246 6.2.1.1 Weldability......Page 249 6.2.1.2 Factors Influencing Electrode Life......Page 251 6.2.1.3 Weld Testing......Page 253 6.2.1.4 High-Strength Steels......Page 254 6.2.1.6 Aluminum......Page 255 6.2.3 Fusion Welding......Page 257 6.2.4 Laser Welding......Page 259 6.2.5 Friction Stir Welding......Page 262 6.3 Adhesive Bonding......Page 264 6.5 Mechanical Fastening......Page 267 Learning Points......Page 269 References......Page 270 7. Corrosion and Protection of the Automotive Structure......Page 272 7.1 Introduction......Page 273 7.2 Relevant Corrosion Processes......Page 274 7.2.1.1 Aluminum Alloys......Page 276 7.2.2 Mechanism of Paint Degradation......Page 277 7.3.1 Styling......Page 279 7.3.3 Panels......Page 280 7.4.1.1 Mode of Application......Page 281 7.4.1.2 Development of a Car Manufacturer's Coated Steel Policy......Page 283 7.4.1.3 Hot-Dip Galvanizing Process......Page 286 7.4.1.4 Relative Performance of Zinc Coatings......Page 288 7.4.1.5 Electrogalvanized Steel Sheet and other Variants......Page 290 7.4.1.6 Other Factors Affecting Performance......Page 291 7.4.2.2 Pretreatment......Page 292 7.4.2.3 Electropriming......Page 293 7.4.2.4 Surfacer......Page 294 7.4.3 Environmental Improvements in the Automotive Paint Process......Page 295 7.4.4 Supplementary Protective Systems......Page 296 7.5.2 Laboratory Tests......Page 298 7.6 Introduction to Electrochemical Methods......Page 300 Learning Points......Page 307 References......Page 309 Objective......Page 312 8.1 Introduction......Page 313 8.2 Effect of Body Mass and Emissions Control......Page 314 8.3 Life-Cycle Analysis......Page 320 8.4.1 The European Recycling Program......Page 328 8.4.2 The Manufacturer's Policy......Page 334 8.4.3 Progress Worldwide......Page 338 8.5 Hygiene......Page 340 8.5.1 Heavy Metal Restrictions......Page 341 8.6.1 Euro NCAP Frontal Impact Test......Page 342 8.6.2 Euro NCAP Car-to-Car Side Impact Test......Page 345 8.6.3 Euro NCAP Side-Impact Pole Test......Page 346 8.6.4 Euro NCAP Pedestrian Protection Tests......Page 347 8.6.5 Improving Safety Performance......Page 348 8.6.6 Influence of Materials......Page 350 8.6.7 Formula 1 Safety Regulations......Page 354 8.6.7.5 Impact Absorber Design......Page 355 Learning Points......Page 357 References......Page 358 9. Future Trends in Automotive Body Materials......Page 360 9.1 Introduction......Page 361 9.2.1 Current Utilization and Vehicle Demographics......Page 363 9.2.2 The Influence of Geography......Page 364 9.2.3 Geographic Development of the Industry......Page 366 9.2.4 The Japanese Influence......Page 368 9.2.4.1 Japanese Methods from a UK/European Perspective......Page 369 9.2.4.3 Supplier Development on a Global Scale......Page 370 9.2.4.4 Manufacturing Utilization......Page 371 9.2.4.5 Co-Ordinated Development......Page 372 9.4 Factors Influencing Material Change in the Future......Page 373 9.4.2 Emissions Control and Fuel Systems......Page 374 9.4.3 Actual BIW Material Effects......Page 376 9.4.4 Recycling and ELV Legislation......Page 378 9.4.5 Effects of Future Design and Engineering Trends......Page 379 9.4.6.1 Forming......Page 382 9.4.6.2 Assembly and Finishing......Page 383 9.4.7.1 Pre-Coated Sheet......Page 384 9.4.7.2 Zinc Coated Steel - PVD Coatings......Page 386 9.4.7.4 Potential for Novel Materials and Forms......Page 388 9.5 Combined Effect of Factors on Materials Utilization within 'Expected' and 'Accelerated' Timescales......Page 390 9.5.1 Possible Consequences Regarding BIW Materials......Page 394 Learning Points......Page 397 References......Page 398 A......Page 400 B......Page 401 C......Page 403 D......Page 405 E......Page 406 F......Page 408 G......Page 409 H......Page 410 I......Page 411 L......Page 412 M......Page 414 P......Page 415 R......Page 418 S......Page 419 T......Page 422 U......Page 424 W......Page 425 Z......Page 426

The selection of automobile body materials is fundamental to the choice of fabrication method, and the characteristics and performance of the final vehicle or component. The factors behind these choices comprise some of the key technological and design issues facing automotive engineers today. Materials for Automobile Bodies brings together a wealth of information on automotive materials and material technologies to provide designers and vehicle body engineers with both a solid grounding and a quick reference to inform their material choices. Coverage includes materials processing, formability, welding and joining, anti-corrosion technologies, plus a comprehensive consideration of the implications of materials selection on these processes.

Dealing with the whole assembly process from raw material to production, right through to recycling at the end of a vehicle's life, this book is the essential resource for practising engineers, designers, analysts and students involved in the design and specification of motor vehicle bodies and components.

• Up-to-date detailed information on contemporary autobody materials, incorporating the explanation often lacking in other data-focused resources
• Includes informative and insightful case studies on the materials and processing choices of major OEMs, including Honda, BMW and Audi
• Now with more on geographical supply and usage trends, environmental concerns and end of life disassembly considerations, and how these affect selection choices

Brings together information on automotive materials and material technologies to provide designers and vehicle body engineers with reference to inform their material choices. This book includes materials processing, formability, welding and joining, anti-corrosion technologies, and the implications of materials selection on these processes.