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CORUS DEVELOPS ALUMINIUM TUBE SPECIFICALLY FOR AUTOMOTIVE STRUCTURES
Although steel will continue to be the most widely used material for automotive body and chassis structures for mass production models, there is a growing demand from vehicle manufacturers for specific applications of aluminium in order to achieve weight savings thereby reducing fuel consumption and emissions. Independent market studies anticipate that in certain vehicle segments, up to 25 per cent of body structure and 20 per cent of chassis parts could be made from aluminium by the end of the decade. Typical body and chassis applications for aluminium tubes will include rear sub-frames, engine cradles, suspension parts and bolt-on body components, such as the radiator support for sports utility and light truck applications. Having developed the technical capability to produce prototype aluminium tube specifically for the automotive industry, Corus is actively marketing the product to European and North American vehicle manufacturers. The Corus aluminium tube combines the lightweight benefits of aluminium with the recognised advantages of using a tubular product in conjunction with processes such as hydroforming, offering carmakers design and cost benefits over existing traditional aluminium conversion technologies such as stamped and welded sheet, castings, forging and extrusions. As with steel, the increased design flexibility offered by a hydroformed aluminium tube product will provide vehicle engineers with an alternative solution for specific applications such as rear-sub frames and engine cradles, which pose particular design challenges. Commenting on the development of aluminium tube and the advantages to carmakers of working with Corus, Johan Ameel, director of Corus Aluminium Rolled Products (CARP), based at the Duffel plant in Belgium, said: 'Corus already has a proven track record in supplying steel tube solutions to the automotive industry, and by tapping into our expertise in aluminium we are now able to offer carmakers a complete portfolio of complementary products in both materials. Combined with the latest processing technologies this will help vehicle manufacturers find the most appropriate solution to reduce vehicle body and chassis component weight depending on the type of vehicle.' Corus aluminium tube products will be made primarily from 5000 series alloys, which offer strong forming capabilities making it suitable for vehicle body and chassis applications. This not only includes the established 5000 series alloys, but also special grades developed by CARP Duffel. For structural body and chassis applications Corus recently developed a new aluminium grade, Templite, which is a high magnesium (Mg>4%)containing alloy with good resistance against intergranular corrosion (IGC) at elevated temperatures. It is very well suited for hydroformed applications, which are subjected to higher temperatures. This alloy will also be available as a sheet product as well as a welded tube, increasing the potential applications.
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