This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Lightweighting of Cars with Aluminum for Better Crashworthiness
Annotation ability available
Sector:
Language:
English
Abstract
Societal demands for greater automotive fuel economy, lower environmental impact and improved performance have produced a trend towards lightweighting in automobiles. In this context, the effect of car mass and size on occupant safety is receiving considerable attention in the literature. Concerns have been raised about the safety of occupants of smaller, lighter cars involved in accidents with larger, heavier vehicles. The evidence supporting these concerns comes from crash data of existing steel-bodied cars.
In this paper, the possibility of using an aluminum body structure to reduce automobile mass is explored. The use of lightweight aluminum provides the opportunity for a larger low mass structure than could be achieved by traditional steel body construction. This paper provides technical data related to the energy-absorbing characteristics of aluminum components. It also suggests that proper alloy selection and proper design can result in a more mass-efficient energy-absorbing structure in the lightweight car. This structure, along with safety devices available today, enable the manufacture of a vehicle providing at least the same level of occupant safety as heavier cars of the past.
Recommended Content
Technical Paper | The Casting Technology for the Aluminum Suspension Cross-Member |
Technical Paper | Analysis of Lightweighting Design Alternatives for Automotive Components |
Technical Paper | AHSS Application in Roof Strength |
Authors
Topic
Citation
Banthia, V., Miller, J., Valisetty, R., and Winter, E., "Lightweighting of Cars with Aluminum for Better Crashworthiness," SAE Technical Paper 930494, 1993, https://doi.org/10.4271/930494.Also In
References
- “Aluminum Body Structures Technology for the Next Decade, The Audi/Alcoa Joint Development Project,” Aluminum Company of America 1985 April
- Glaser K. F. Johnson G. E. “Construction Experience on Aluminum Experimental Body,” SAE Technical Paper 740075 1974
- Burst H. E. Bäurerle H. P. Thull W. F. “The All-Aluminum Auto Body - A Study Based on the Porshe 928,” SAE Technical Paper 830094 1983
- Wheeler M. J. Sheasby R. G. Kewley D. “Aluminum Structural Vehicle Technology - A Comprehensive Approach to Vehicle Manufacturing in Aluminum,” SAE Technical Paper 870146 1987
- Brooke L. Kobe G. McElroy J. “The Case for Contour,” Automotive Industries 1991 25
- Winter E. F. M. Sharp M. L. Nordmark G. E. Banthia V. K. “Design Considerations for Aluminum Automotive Spaceframe Structures,” Technical Papers of the XXIII FISITA Congress Torino, Italy 1990 May 11 2 465 471
- Bäurerle H. P. Burst H. E. “Current Status and Future Prospects of Car Body Weight Reduction,” Science and Engineering of Light Metals Hirano K. Oikawa H. Ikeda K. Published by the Japan Institue of Light Metals Tokyo 1991
- Komatsu Y. et al. “Application of All-Aluminum Automotive Body for Honda NSX,” SAE Technical Paper 910548 , SAE 1991
- “Report to the National Academy of Sciences Committee on Fuel Economy of Automobiles and Light Trucks,” The Aluminum Association July 8 1991 7 9
- Sharp M. L. McClure R. H. G. “The Practicality of Aluminum for Automotive Body Structure,” Automotive Technology International ‘92 77 81 Stering Publications International Ltd. London, UK
- Evans L. Frick M. C. “Car Size or Car Mass: Which Has Greater Influence on Fatality Risk?” American Journal of Public Health August 1992 82 8
- Evans L. Frick M. C. “Mass Ratio and Relative Driver Fatality Risk in Two Vehicle Crashes,” Submitted for Publication to Accident Analysis and Prevention,” 1992
- Baumann K.-H. Goesch L. Holtze H. Schwede W. “Frontal Offset Crash testing for Approxzimately 15 Years: Results, Experiences, and Consequences,” SAE Technical Paper 900413 in Vehicle Crashworthiness and Occupant Protection in Frontal Collisions, SAE SP-807 February 1990
- “Automotive Fuel Economy, How Far Should We Go?,” Chapter 3. Safety Implications of Fuel Economy Issues,” Committee on Fuel Economy of Automobiles and Light Trucks - National Research Council National Academy Press Washington, D.C. 1992
- Graham J. D. “The Safety Risks of New Fuel Economy Legislation,” Risks Issues in Health and Safety Spring 1992
- O'Neil B. Joksch H. Haddon W. Jr. “Empirical Relationships Between Car Size, Car Weight, and rash Injuries in Car-to-Car Crashes,” Proc. 5th Int. Tech. Conf. on Exp. Safety Vehicles June 4 - 7 1974 London, UK
- Brownlee M. et al. “Implications of the New Car Assessment Program for Small Car Safety,” 8th ESV Conference 1980
- Hakney J. Quarles V. “The New Car Assessment Program - Status and Effect,” 9th ESV Conference Kyoto, Japan 1982
- Ventre P. “Homogeneous Safety Amid Heterogeneous Car Population,” 3rd ESV Conference Washington, D.C 1972
- Mitsuhashi L. et al. “On Crashworthiness of Nissan ESV,” SAE Technical Paper 740208 1974
- Danckert H. “Development of Crash Energy Management Solution,” SAE Technical Paper 760793 1976
- Danner M. et al. “Aspects in Optimizing Car Structures and Passenger Car Structures and Passenger Prtotection by a Comprehensive Analysis of Car-to-Car and Car-to-Object Collisions,” SAE Technical Paper 850514
- Seeds A. D. McGregor I. J. “Aluminum Automobile Structural Crashworthiness,” (Appendix to the “Report to the National Academy of Sciences Committee on Fuel Economy of Automobiles and Light Trucks,”) The Aluminum Association July 8 1991
- Lindholm U. S. et al “Effect of Strain Rate on Yield Strength, Tensile Strength, and Elongation of Three Aluminum Alloys,” Journal of Materials 6 1 119 133 1971
- Specifications for Aluminum Structures Fifth Aluminum Association Washington, D. C. 1988
- Illustrative Examples of Design Based on Specifications for Aluminum Structures Fifth Edition Aluminum Association Washington, D. C. 1978
- DiPaolo B. A. “An Experimental and Analytical Investigation of the Axial Crush on an Aluminum Box Section,” Thesis submitted to The University of Pittsburgh 1992
- Mahmood H. F. Paluszny A. “Stability of Plate-Type Box Columns Under Crush Loading,” Computational Methods in Ground Transportation Vehicles Kamal M. M. Wolf J. A. Winter Annual Meeting of the American Society of Mechanical Engineers Phoenix 1982 November 14-19
- Armao F. G. Long R. S. Winter E. F. M. Woithe H. E. O. “Joining Techniques for Aluminum Castings, Extrusions and Sheet,” presented at the Aluminium Zentrale Seminar “Fügen von Aluminium” (“Joining of Aluminum”), Neu-Ulm, Federal Republic of Germany,” 1992 February 25-26