Automotive Sheet Metal Component Conversion From Steel to Aluminum

A manufacturing study has been conducted to determine the feasibility of direct substitution of aluminum sheet for steel in automotive sheet metal applications. Manufacturing considerations, strength-weight relationships and design parameters have been analyzed and the conclusion reached that aluminum panels can be manufactured on a production basis but the use of aluminum for a show surface panel made on tools built for steel with a gage for gage substitution of material is not recommended at this time because of inherent manufacturing penalties.