scholarly journals Lightweight in Automotive Components by Forming Technology

2020 ◽  
Vol 3 (3) ◽  
pp. 195-209 ◽  
Author(s):  
Stephan Rosenthal ◽  
Fabian Maaß ◽  
Mike Kamaliev ◽  
Marlon Hahn ◽  
Soeren Gies ◽  
...  
Keyword(s):  
High Performance ◽  
Lightweight Design ◽  
Dissimilar Materials ◽  
Hot Extrusion ◽  
High Strength ◽  
Extrusion Process ◽  
Specific Strength ◽  
Metal Metal ◽  
Fiber Metal ◽  
Strength And Stiffness

AbstractLightweight design is one of the current key drivers to reduce the energy consumption of vehicles. Design methodologies for lightweight components, strategies utilizing materials with favorable specific properties and hybrid materials are used to increase the performance of parts for automotive applications. In this paper, various forming processes to produce light parts are described. Material lightweight design is discussed, covering the manufacturing processes to produce hybrid components like fiber–metal, polymer–metal and metal–metal composites, which can be used in subsequent deep drawing or combined forming processes. Approaches to increasing the specific strength and stiffness with thermomechanical forming processes as well as the in situ control of the microstructure of such components are presented. Structure lightweight design discusses possibilities to plastically form high-strength or high-performance materials like magnesium or titanium in sheet, profile and tube forming operations. To join those materials and/or dissimilar materials, new joining by forming technologies are shown. To economically produce lightweight parts with gears or functional elements, incremental sheet-bulk metal forming is presented. As an important part property, the damage evolution during the forming operations will be discussed to enable even lighter parts through a more reliable design. New methods for predicting and tailoring the mechanical properties like strength and residual stresses will be shown. The possibilities of system lightweight design with forming technologies are presented. A combination of additive manufacturing and forming to produce highly complex parts with integrated functions will be shown. The integration of functions by a hot extrusion process for the manufacturing of shape memory alloys is presented. An in-depth understanding of the newly developed processes, methodologies and effects allows for a more accurate dimensioning of components. This facilitates a reduction in the total mass and an increasing performance of vehicle components.

scholarly journals Materials for Automotive Lightweighting

2019 ◽  
Vol 49 (1) ◽  
pp. 327-359 ◽  
Author(s):  
Alan Taub ◽  
Emmanuel De Moor ◽  
Alan Luo ◽  
David K. Matlock ◽  
John G. Speer ◽  
...  
Keyword(s):  
Galvanic Corrosion ◽  
Low Carbon Steel ◽  
High Strength Steels ◽  
High Strength ◽  
Low Carbon ◽  
New Materials ◽  
Specific Strength ◽  
Advanced High Strength Steels ◽  
Strength And Stiffness ◽  
The Cost

Reducing the weight of automobiles is a major contributor to increased fuel economy. The baseline materials for vehicle construction, low-carbon steel and cast iron, are being replaced by materials with higher specific strength and stiffness: advanced high-strength steels, aluminum, magnesium, and polymer composites. The key challenge is to reduce the cost of manufacturing structures with these new materials. Maximizing the weight reduction requires optimized designs utilizing multimaterials in various forms. This use of mixed materials presents additional challenges in joining and preventing galvanic corrosion.

Influence of the base material on the mechanical behaviors of polycrystal-like meta-crystals

2021 ◽  
pp. 2150004
Author(s):  
J. Lertthanasarn ◽  
C. Liu ◽  
M.-S. Pham
Keyword(s):  
Synergistic Effects ◽  
High Surface ◽  
Base Material ◽  
High Strength ◽  
Yield Stability ◽  
Yield Behavior ◽  
Specific Strength ◽  
Base Materials ◽  
Lattice Materials ◽  
Strength And Stiffness

Architected lattice metamaterials offer extraordinary specific strength and stiffness that can be tailored through the architecture. Meta-crystals mimic crystalline strengthening features in crystalline alloys to obtain high strength and improved post-yield stability of lattice materials. This study investigates synergistic effects of the base material’s intrinsic crystalline microstructure and architected polycrystal-like architecture on the mechanical behavior of architected metamaterials. Four different polygrain-like meta-crystals were fabricated from 316L, Inconel 718 (IN718) and Ti6Al4V via laser powder bed fusion (L-PBF). While the elastic modulus of the meta-crystals did not vary significantly with the base material or the number of meta-grains, the strength of the meta-crystals showed strong increasing correlation with reducing the size of meta-grains. The differences between meta-crystals made by the three alloys were the most substantial in the post-yield behavior, where the 316L meta-crystals were the most stable while Ti6Al4V meta-crystals were the most erratic. The differences in the post-yield behavior were attributed to the base material’s ductility and intrinsic work-hardening. For all base materials, increasing the number of meta-grains improved the post-yield stability of meta-crystals. The tolerance to the processing defects also differed with the base material. Detrimental defects such as the high surface roughness on the downskin of the struts or the large, irregularly shaped pores near the surface of the struts led to early strut fracture in Ti6Al4V meta-crystals. In contrast, ductile IN718 was able to tolerate such defects, enabling the most significant synergistic strengthening across lengthscales to achieve architected materials of low relative density, but with a very high strength and an excellent energy absorption.

Forming Potential of Steel/Polymer/Steel Sandwich Composites with Local Plate Inserts

2012 ◽  
Vol 706-709 ◽  
pp. 681-686 ◽  
Author(s):  
Heinz Palkowski ◽  
Olga Sokolova ◽  
Adele Carradò
Keyword(s):  
Deep Drawing ◽  
High Performance ◽  
High Strength ◽  
Metal Plate ◽  
Elastic Behaviour ◽  
Forming Limit ◽  
Sandwich Composites ◽  
Strength And Stiffness ◽  
Naval Engineering ◽  
Forming Behaviour

High-performance metal/polymer/metal hybrid sandwich composites are attractive materials for lightweight constructions in automotive, aerospace and naval engineering world-wide. Due to the excellent combination of mechanical, thermal and elastic properties and, as a result of high forming potential, they can be used in areas of high vibration, where high damping properties of the polymer are demanded and at the same time high strength and stiffness are given by the metal. Disadvantages can be given in case of mechanical or thermal joining of these polymer-based sandwiches because of the elastic behaviour as well as low melting temperature of the polymer. Local metal plate insertions in the soft core at the place of joining can be a solution for such kind of problems. But forming behaviour of sandwich materials with and without local inlays differs strongly. Sandwich composites of that type were produced by roll-bonding. Their quality and their position were controlled by Lockin thermography. The forming behaviour of sandwiches with different geometry, size, type and the position of the inlays was tested by deep drawing and bending and analysed with the help of digital photogrammetry and compared to experimentally obtained mechanical properties. As a result, the local inlays, as well as their geometry, size and type strongly influence the forming limit conditions. The differences in flow behaviour of non-reinforced and reinforced sandwich regions after deep drawing and bending will be presented, as well as the influence of the position of the inlays.

Mechanical Properties of Densified Untwisted Carbon Nanotube Yarn / Epoxy Composites

2015 ◽  
Author(s):  
Risa Yoshizaki ◽  
Kim Tae Sung ◽  
Atsushi Hosoi ◽  
Hiroyuki Kawada
Keyword(s):  
Mechanical Properties ◽  
Volume Fraction ◽  
Polymer Matrix Composites ◽  
High Strength ◽  
Matrix Composites ◽  
Specific Strength ◽  
The Matrix ◽  
Cnt Arrays ◽  
Strength And Stiffness ◽  
Long Fibers

Carbon nanotubes (CNTs) have very high specific strength and stiffness. The excellent properties make it possible to enhance the mechanical properties of polymer matrix composites. However, it is difficult to use CNTs as the reinforcement of long fibers because of the limitation of CNT growth. In recent years, a method to spin yarns from CNT forests has developed. We have succeeded in manufacturing the unidirectional composites reinforced with the densified untwisted CNT yarns. The untwisted CNT yarns have been manufactured by drawing CNTs through a die from vertically aligned CNT arrays. In this study, the densified untwisted CNT yarns with a polymer treatment were fabricated. The tensile strength and the elastic modulus of the yarns were improved significantly by the treatment, and they were 1.9 GPa and 140 GPa, respectively. Moreover, the polymer treatment prevented the CNT yarns from swelling due to impregnation of the matrix resin. Finally, the high strength CNT yarn composites which have higher volume fraction than a conventional method were successfully fabricated.

scholarly journals Study on the Influence of Processing Parameters on Piercing Extrusion Process of Large Diameter Cupronickel Alloy Pipes Using 3D FEM Analysis

2017 ◽  
Vol 2017 ◽  
pp. 1-10 ◽  
Author(s):  
Jun Cai ◽  
Kuaishe Wang ◽  
Bing Zhang ◽  
Wen Wang
Keyword(s):  
High Performance ◽  
Rapid Development ◽  
Large Diameter ◽  
Fem Analysis ◽  
Hot Extrusion ◽  
Processing Parameters ◽  
Extrusion Process ◽  
Ingot Casting ◽  
3D Fem ◽  
Deformation Parameters

With the rapid development of the shipping and the power industry, the demand for high-performance cupronickel alloy pipes is greatly increasing. The main processing methods of this alloy include semisolid ingot casting and deformation by hot extrusion. Many defects appear during the hot extrusion process for large diameter cupronickel alloy pipes, which results in considerable problems. Therefore, numerical simulation of hot extrusion for cupronickel alloy pipes before the practical production is of vital significance to properly determine the deformation parameters. In order to obtain the influence of processing parameters on the piercing extrusion process of large diameter cupronickel alloy pipe, metal flowing law under different deformation conditions was simulated and analyzed via employing a 3D FEM code. The results showed that piercing speed had no obvious influence on the cupronickel alloy billet. However, the friction had significant influence on the piercing process of cupronickel alloy billet: with the increase of friction coefficient, the temperature and the load increased.

scholarly journals Nanographitic coating enables hydrophobicity in lightweight and strong microarchitected carbon

2020 ◽  
Vol 1 (1) ◽  
Author(s):  
Akira Kudo ◽  
Federico Bosi
Keyword(s):  
Joule Heating ◽  
Mechanical Response ◽  
High Strength ◽  
Pyrolytic Carbon ◽  
Low Density ◽  
Water Contact ◽  
Specific Strength ◽  
The Mean ◽  
Strength And Stiffness ◽  
Coated Carbon

Abstract Metamaterials that are lightweight, stiff, strong, scalable and hydrophobic have been achieved separately through different materials and approaches, but achieving them in one material is an outstanding challenge. Here, stereolithography and pyrolysis are employed to create carbon microlattices with cubic topology and a strut width of 60–70 µm, with specific strength and stiffness of up to 468.62 MPa cm3 g−1 and 14.39 GPa cm3 g−1 at a density of 0.55 g cm−3, higher than existing microarchitected materials and approaching those of the strongest truss nanolattices. Subsequent fast Joule-heating then introduces a hierarchical nanographitic skin that enables hydrophobicity, with a water contact angle of 135 ± 2°, improving the hydrophilic response of pyrolytic carbon. As the Joule heating induced sp2-hybridization and nano-texturing predominantly affect the strut sheath, the effect on mechanical response is limited to a reduction in the distribution of compressive strength of as-pyrolyzed architectures by ~80% and the increase of the mean effective stiffness by ~15%. These findings demonstrate a technique to fabricate high strength, low density, and hydrophobic nanographite-coated carbon microlattices.

scholarly journals Natural Silkworm Cocoon Composites with High Strength and Stiffness Constructed in Confined Cocooning Space

Polymers ◽  
2018 ◽  
Vol 10 (11) ◽  
pp. 1214 ◽  
Author(s):  
Lan Cheng ◽  
Xiaoling Tong ◽  
Zhi Li ◽  
Zulan Liu ◽  
Huiming Huang ◽  
...  
Keyword(s):  
High Performance ◽  
High Strength ◽  
Homogeneous Layer ◽  
Dense Layer ◽  
Test Results ◽  
Young’S Moduli ◽  
Layer Structures ◽  
Potential Applications ◽  
Silkworm Cocoon ◽  
Strength And Stiffness

In this study, using round paper tubes (PTs) and rectangular cardboard boxes (CBs) as external constraints to control the size of the cocooning space, we fabricated a series of modified silkworm cocoons (PT cocoons and CB cocoons). Their microstructures, morphologies, compositions, and mechanical properties were characterized and compared with normal silkworm cocoons. These two kinds of modified silkworm cocoons exhibit dense and homogeneous layer structures. Tensile test results indicate that above a size limit of cocooning space, their tensile strengths, Young’s moduli, and strain energy densities increase with the decrease in cocooning space. Especially in comparison with the normal cocoons, the tensile strength and Young’s modulus of the PT-14 cocoon increase by 44% and 100%, respectively. Meanwhile, PT cocoons and CB cocoons, except PT-12, also possess better peeling resistance than normal cocoons. Owing to the dense structure and low porosity, the modified cocoons form robust fiber networks that result in high strength and toughness. This study provides a green and efficient method to fabricate mechanically enhanced silkworm cocoons with special shapes and dense layer structures. The method can be easily subjected to further modification processes and has potential applications in the production of high-performance green cocoon composites and biomimetic materials.

High-Performance Polymer Fibers

MRS Bulletin ◽  
1987 ◽  
Vol 12 (8) ◽  
pp. 22-26 ◽  
Author(s):  
W. Wade Adams ◽  
R. K. Eby
Keyword(s):  
Mechanical Properties ◽  
High Performance ◽  
Covalent Bond ◽  
High Strength ◽  
Aromatic Polyamide ◽  
Chain Molecules ◽  
Ordered Array ◽  
New Ideas ◽  
Strong Motivation ◽  
Strength And Stiffness

Since the pioneering work of Carothers which led to the introduction of strong nylon fibers by DuPont in the 1930s, polymer scientists have pursued the development of high-performance fibers to replace natural or metallic products, both to improve mechanical properties and to reduce weight. That development was relatively slow and evenly paced until DuPont again revolutionized the field with the release of Kevlar™, an aromatic polyamide with unprecedented mechanical properties. Since then, the field has literally boomed with new developments, and now organic fibers are available with properties that compete with the best inorganics and are far superior to metal fibers.Strong motivation for the invention of new organic fibers comes from the aerospace industry, which seeks fibers to use in reinforced composite structural materials. Composites bring new advances in stiffness (airplane wings can't bend too much!) in weight savings (every kilogram saved in the structure of an airplane saves $120 over its lifetime, and in a spacecraft $10,000), and in radically new ideas, such as radar-invisibility (stealth)5 and mission-adaptive wings (in-flight variable-shape wings). Hence, for a variety of specialty applications, otherwise commercially indefensible materials become viable.It may be somewhat counter intuitive to materials scientists unfamiliar with polymers to expect polymer mechanical properties to be greater than in the best metals. The origin of high strength and stiffness in a polymer fiber is the covalent bond, especially when aligned in an ordered array of long chain molecules.

In-Situ Solid-State Synthesis of Mg Composite with Mg2Si Dispersoids

2005 ◽  
Vol 475-479 ◽  
pp. 497-500
Author(s):  
Ritsuko Tsuzuki ◽  
Katsuyoshi Kondoh
Keyword(s):  
Mechanical Properties ◽  
Solid State ◽  
High Performance ◽  
Extrusion Direction ◽  
Hot Extrusion ◽  
Extrusion Process ◽  
Synthesis Temperature ◽  
Solid State Synthesis ◽  
Casting Alloys

Super light and high performance Mg2Si/Mg composites, which had excellent mechanical properties, were developed via the combination of solid-state synthesis and hot extrusion process. In this study, cold compacting (CP) and repeated plastic working (RPW) were firstly carried out for the mixture of Mg-Si powders, and the refinement of both Mg grains and dispersoids. Each specimen was evaluated by observation of microstructure and tensile test. As a result, it was understood that Mg2Si dispersoids were refined and dispersed into Mg matrix, and were flowed along extrusion direction. And their mechanical properties were higher than the conventional die casting alloys. Also the effect of RPW as the improvement of properties and the decrease of synthesis temperature were confirmed.

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