Cost-efficient designs of aluminum autobody structures consist mainly of stampings
using conventional technology. Progress in metallurgy and forming processes has enabled
aluminum body panels to achieve significant market share, particularly for hoods. Fast bake
hardening alloys with better hemming performance were developed for improved outer panel sheet
products. Specific guidelines for handling and press working were established to form aluminum
panels using similar schedules and production lines as steel parts. Stamping productivity was
improved by optimization of the trimming process to reduce sliver/particle generation and resulting
end-of-line manual rework. Both hemming formability and trimming quality not only depend on
tooling setup but also on microstructural features, which govern intrinsic alloy ductility. Targets for
the next high volume aluminum car body applications, such as roof panels and doors, require higher
strength and/or better formability. The challenges of complex stampings can be met with optimized
alloys and lubricants, with improved numerical simulation to fine-tune stamping process
parameters, and with the introduction of new technologies. Warm forming was examined as a
potential breakthrough technology for high volume stamping of complex geometries.
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