aluminium in commercial vehicles - European Aluminium Association

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C O N T E N T S I. FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 II. ALUMINIUM IN TRANSPORT . . . . . . . . . . . . . . . . 7 1. One century of aluminium in transport . . . . . . . . . . . . . . . . 8 2. Evolution of commercial vehicles . . . . . . . . . . . . . . . . . . . . 12 3. Aluminium applications and weight savings . . . . . . . . . . . 13 4. Today’s concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 III. WHY USING ALUMINIUM . . . . . . . . . . . . . . . . . . 15 1. Short pay-back . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2. Aluminium performance properties . . . . . . . . . . . . . . . . . . 18 3. Environmental and social Benefits . . . . . . . . . . . . . . . . . . . 22 4. On the road… . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 IV. FREQUENTLY ASKED QUESTIONS . . . . . . . . . . 29 1. Aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2. Aluminium chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 3. Aluminium tippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 4. Aluminium tankers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 V. ALUMINIUM ALLOYS FOR COMMERCIAL VEHICLES . . . . . . . . . . . . . . 39 1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2. International product designation . . . . . . . . . . . . . . . . . . . 41 3. Basic temper designations . . . . . . . . . . . . . . . . . . . . . . . . . 42 4. Subdivisions of H temper designations . . . . . . . . . . . . . . . 42 5. Subdivision of T temper designations . . . . . . . . . . . . . . . . 43 6. Typical alloys for commercial vehicles . . . . . . . . . . . . . . . . 44 7. Influence of temperature on mechanical properties . . . . 50 8. Influence of fabrication on the properties of the alloys . 52 9. List of standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 VI. DESIGN AND CALCULATION . . . . . . . . . . . . . . . 57 1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 2. Possibilities with aluminium . . . . . . . . . . . . . . . . . . . . . . . . 58 3. Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 4. Aluminium versus Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 5. Limit state design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 6. Serviceability limit state . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 7. Ultimate limit state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 8. Fatigue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 9. Special design issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 10. References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
VII. FABRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 2. Fabrication of products from plate . . . . . . . . . . . . . . . . . . 93 3. Fabrication of products from extrusions . . . . . . . . . . . . . . 98 4. Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 5. Tapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 6. Deep Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 7. Spinning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 VIII. WELDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 2. TIG welding (Tungsten Inert Gas) . . . . . . . . . . . . . . . . . . . 109 3. MIG welding (Metal Inert Gas) . . . . . . . . . . . . . . . . . . . . . 110 4. Plasma MIG welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 5. Laser welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 6. Laser MIG welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 7. Resistance welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 8. FSW - Friction Stir Welding . . . . . . . . . . . . . . . . . . . . . . . . 120 9. Surface preparation before welding . . . . . . . . . . . . . . . . 122 10. Quality control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 11. Design and prevention of deformation . . . . . . . . . . . . . . 126 IX. OTHER JOINING TECHNIQUES . . . . . . . . . . . . 129 1. Adhesive bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 2. Screwing and bold fastening . . . . . . . . . . . . . . . . . . . . . . 133 3. Riveting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 4. Snap-Lock & Clipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 X. DECORATION AND FINISHING . . . . . . . . . . . . 137 1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 2. Possibilities with aluminium . . . . . . . . . . . . . . . . . . . . . . . 138 3. Mechanical finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 4. Chemical decoration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 XI. CORROSION RESISTANCE . . . . . . . . . . . . . . . . . . . 145 1. Definition of corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 2. Corrosion of aluminium . . . . . . . . . . . . . . . . . . . . . . . . . . 146 XII. CLEANING OF ALUMINIUM COMMERCIAL VEHICLES . . . . . . . . . . . . . . . . . . . 153 1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 2. The nature of stains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154 3. The choise of detergent . . . . . . . . . . . . . . . . . . . . . . . . . . 155 4. Application of the detergent . . . . . . . . . . . . . . . . . . . . . . 155 XIII. REPAIR OF ALUMINIUM COMMERCIAL VEHICLES . . . . . . . . . . . . . . . . . . . 157 1. Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158 2. Execution of repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 3. Repair of aluminium chassis . . . . . . . . . . . . . . . . . . . . . . . . 159 4. MIG and TIG weld repairs . . . . . . . . . . . . . . . . . . . . . . . . . 160 Acknowledgments and photo credits . . . . . . . . . . . . . . . .162
Page 1 and 2: ALUMINIUM IN COMMERCIAL VEHICLES
Page 3: Aluminium in Commercial Vehicles ha
Page 7 and 8: CHAPTER II ALUMINIUM IN TRANSPORT 1
Page 9 and 10: EUROPEAN ALUMINIUM ASSOCIATION ALUM
Page 15 and 16: CHAPTER III WHY USING ALUMINIUM 1.
Page 29 and 30: CHAPTER IV FREQUENTLY ASKED QUESTIO
Page 39 and 40: CHAPTER V ALUMINIUM ALLOYS FOR COMM
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EUROPEAN ALUMINIUM ASSOCIATION ALUM
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CHAPTER VI DESIGN AND CALCULATION 1
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CHAPTER VII FABRICATION 1. INTRODUC
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CHAPTER VIII WELDING 1. FOREWORD .
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CHAPTER IX OTHER JOINING TECHNIQUES
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CHAPTER X DECORATION AND FINISHING
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Cell wall EUROPEAN ALUMINIUM ASSOCI
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CHAPTER XI CORROSION RESISTANCE 1.
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CHAPTER XII CLEANING OF ALUMINIUM C
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CHAPTER XIII REPAIR OF ALUMINIUM CO
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