Davies G. Materials for Automobile Bodies

Butterworth-Heinemann
An imprint of Elsevier
Linacre House, Jordan Hill, Oxford OX2 8DP
200 Wheeler Road, Burlington MA 01803
First published 2003
Copyright 2003, Elsevier Ltd. All rights reservedThe selection of automobile body materials is fundamental to the choice of fabrication method, and the characteristics and performance of the final vehicle or component. The factors behind these choices comprise some of the key technological and design issues facing automotive engineers today.Materials for Automobile Bodies presents detailed up-to-date information on material technologies for the automobile industry, embracing steels (including high-strength steels) aluminium, plastics, magnesium, hydro-forming and composite body panels. Coverage also includes: materials processing; formability; welding and joining; anti-corrosion technologies; plus a comprehensive consideration of the implications of materials selection on these processes. Dealing with the whole assembly process from raw material to production, right through to recycling at the end of a vehicle's life, this book is the essential resource for practicing engineers, designers, analysts and students involved in the design and specification of motor vehicle bodies and components.Preface vii
Acknowledgements ix
About the author xi
Disclaimer xiiiOverview of content
Materials overview
General format of presentation
ntroduction to body architecture and terminologyDesign and material utilizationHistorical perspective and evolving materials technology
Finite element analysis
One manufacturer’s approach to current design
Panel dent resistance and stiffness testing
Fatigue
Alternative body architecture
ntegration of materials into designs
Engineering requirements for plastic and composite components
Cost analysis
Learning points from ChapterMaterials for consideration and use in automotive body structuresMaterial candidates and selection criteria
Aluminium
Magnesium
Polymers and composites
Learning points from ChapterThe role of demonstration, concept and competition carsThe BL Energy Conservation Vehicle (ECV 3) and aluminium
structured vehicle technology (ASVT)
ULSAB and ULSAB
Concept cars
Competition cars
Key learning points from ChapterComponent manufacture
Steel formability
Aluminium formability
Manufacture of components in magnesium
Production of polymer parts
Learning points from ChapterComponent assembly: materials joining technologyWelding
Adhesive bonding
Mechanical fastening
Learning points from ChapterCorrosion and protection of the automotive structureRelevant corrosion processes
Effective design principles
Materials used for protection of the body structure
Empirical vehicle and laboratory comparisons
An introduction to electrochemical methods
Learning points from ChapterEnvironmental considerationsEffect of body mass and emissions control
Life cycle analysis (LCA)
Recycling and ELV considerations
Hygiene
BIW design for safety
Learning points from ChapterFuture trends in automotive body materialsFactors influencing material change in the future – trends and
requirements
Combined effect of above factors on materials utilization within
‘expected’ and ‘accelerated’ timescales
Learning points from Chapter