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Table of contents
2 Body components and modules ........................................................................................... 2
2.1 Engine cradles and engine mounts ................................................................................. 2
2.2 Suspension strut domes ................................................................................................ 8
2.3 Front end carriers...................................................................................................... 12
2.4 Cross car beam (instrument panel support) .................................................................... 13
2.5 Rear frame .............................................................................................................. 16
2.6 Other aluminium components in the body structure ......................................................... 17
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2 Body components and modules
Structural aluminium components and modules can be safely integrated into a steel body
structure. There are different methods for joining aluminium to steel which fulfil highest
requirements. However, when the integration of structural aluminium components and modules
into a steel body structure is considered, solutions must be sought for two issues:
- Aluminium/steel joints have to be designed and/or properly protected to safely avoid
any possibility of galvanic corrosion.
- Potential problems due to the different thermal expansion coefficients of steel
and aluminium must be accounted for in the design process.
Proven and tested corrosion protection methods are readily available. The necessary
precautions depend on the specific application and the selected joining technique, but
when the proper measures are taken, long term performance of the assembled mixed
material structure can be guaranteed.
Thermal expansion effects are of little relevance under normal service conditions. Thus, the
installation of structural aluminium components and modules into the lacquered body-in-
white (BIW) presents in general no problems.
More difficult is the integration of aluminium components into a steel body structure in the
body shop, i.e. ahead of the lacquering operation of the BIW. In this case, it is essential to
prevent (or minimize) the formation of residual internal stresses or the occurrence of
geometrical distortions due to the difference in the thermal expansion coefficients of the two
metals. The critical step is the temperature change during lacquer bake hardening, in
particular during the hardening of the first lacquer layer of the cathodic electro-coating
process which takes place in the temperature range 170 180 C. As a consequence,
single aluminium components are seldom integrated already into a steel BIW, but mostly
attached later in the assembly plant into the already lacquered car body.
2.1 Engine cradles and engine mounts
The primary function of the engine cradle is to provide structural support for various
subsystems of the car. It locates in particular the following components relative to the
body structure:
- Powertrain assembly (i.e. the engine and transmission mounts)
- Front suspension module (lower control arms and stabilizer bar)
- Steering system.
Furthermore, it protects the powertrain components from incidental ground contact
and significantly contributes to the structural rigidity and safety of the overall car body.
The engine cradle is an important structural element in the front of the vehicle and, thus,
an interesting candidate for lightweighting with aluminium. Different design approaches
have been evaluated. As a first example, the sheet-intensive aluminium engine cradle
developed for the Ford P2000 (1998) is shown below.
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Aluminium engine cradle developed for the Ford P2000
The all-aluminium engine cradle shown above was assembled using two castings, a
hydroformed tube and eight formed sheet parts. The weight of the aluminium assembly was
14.4 kg compared to the 21.7 kg for the original steel assembly, i.e. the weight of the engine
cradle could be reduced by one third. Probably even important from a cost-efficiency point
of view was the reduction of the number of parts from 21 steel parts to 11 aluminium parts.
An extrusion-based engine cradle for a midsize, front wheel drive car was developed by
General Motors and produced in high volumes (300000 units per year). The start of
production was 1999. The specifications are:
- Dimensions: (L / W / H in mm): 1140 / 1190 / 230
- Finished part weight (in kg): 17.0
Compared to the steel solution, a weight reduction of 32 % was achieved (with a
simultaneous increase of the stiffness). The number of parts could be reduced from 24
(steel) to 17 (aluminium).
Extrusion-based aluminium engine cradle
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The GM engine cradle consisted of 15 straight, machined extrusions and two small sheet
stampings. The applied extrusion alloys were EN AW-6061 (in the tempers T4 and T6) and
EN AW-6063-T4. The use of extrusions allowed to place the material exactly where needed;
the applied wall thicknesses varied between 3.0 and 20.5 mm. The sheet material was EN
AW-6061 (gauge 4.8 mm). The cradle was assembled by robotic MIG welding. First, the
front module and rear module subassemblies were produced and then joined with the side
rails into a square assembly. Finally, the brackets were attached.
Extrusion-based aluminium engine cradle used for the Chevrolet Monte Carlo and
Impala models
(Source: Magna)
All-aluminium assembled engine cradle
(Photo: A.O.Smith)
Another example of an assembled engine cradle is shown above. It consists of 15
extruded parts, a formed sheet part and a few cover plates and demonstrates again the
advantages offered by the application of the aluminium extrusion technology. An optimized
extrusion-based design offers the possibility to integrate many additional functions into the
structural component.
Similar possibilities, but without the need for complicated assembly operations are offered by
high quality aluminium castings. Consequently, modern engine cradle design concepts
rather use cast aluminium components.
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Cast engine cradle of the Mercedes-Benz S class (W220)
Cast aluminium engine cradle of the Mercedes-Benz C class (C204)
(Photo: Aluminium Rheinfelden)
The engine cradle of the Mercedes-Benz C class is produced from the high quality casting
alloy Silafont
-
36 (AlSi9MgMn) for the BMW 6-cylinder engine N52. It is used in the as-cast state. The
application of high quality aluminium casting alloys like Silafont
-300 can be also advantageously used for the front longitudinal beam.
The formability requirements for the production of this component are somewhat relaxed,
i.e. it is possible to apply the material in the age hardened T61 temper. Thus it is possible to
realize 20 % weight reduction compared to the equivalent part in the traditionally used alloy
EN AW-5754 (or approx. 6 kg per vehicle).
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Application of the alloy Anticorodal