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Viewing 1 to 18 of 18
2012-09-10
Technical Paper
2012-01-1874
Brandon Bodily, Markus Heinimann, Gary Bray, Edward Colvin, Jeffrey Witters
The challenging performance and affordability goals of next generation aircraft have accelerated the demand for advanced structural materials and concepts capable of achieving significant weight and cost (acquisition and operational) reduction. To meet these aggressive weight and structural maintenance reduction targets, future aircraft will require structural solutions that provide increased strength, damage tolerance and corrosion resistance. Alcoa has developed advanced aluminum alloys and third generation aluminum-lithium (Al-Li) alloys with exceptional performance and durability capability. This presentation first introduces the basic properties of the new 2xxx and 7xxx series aerospace aluminum and third generation Al-Li alloys possessing improved strength, fatigue life, crack propagation, fracture toughness, corrosion resistance, and, in the case of Al-Li alloys, reduced density and increased modulus.
2012-04-16
Technical Paper
2012-01-0793
Ken Archibald, Wilson Lee, Matthew Brest
A method of developing more representative test factors and respective minimum cycles is proposed in practices such as J328 and J2530. The method includes recent 6061-T6 material fatigue characterization from specimens originating in wheels. The characterization uses a fully reversed (R=−1) loading method and the specimen is in un-notched condition. Results of finite element analyses of different wheel designs are observed to verify the proposition of usage of R= −1 as appropriate for such material characterization. The results of recent fatigue response of 6061-T6 indicate that the accelerated test load factors found in SAE J328 and SAE J2530 can be reduced by 10%, while rendering at least the same structural margin as that of other ferrous and nonferrous materials. SAE J2562 illustrates a methodology for testing the structural adequacy of a wheel design using loads and cycles that more closely replicate on-vehicle service than those of J328 and J2530.
1993-03-01
Technical Paper
930277
J. M. Story, G. W. Jarvis, H. R. Zonker, S. J. Murtha
Aluminum sheet forming is entering an era where rapid advances in technology are likely. Combining increased understanding of material behavior, increased understanding of metalworking tribology and improved control of sheet forming processes will result in improved distribution of strain, allowing more complex components to be formed and greater design flexibility. New process control techniques will be developed and implemented to result in improved press actions, control of strain path to effect increased formability and reduced sensitivity to process variables. Improved techniques for assessing producibility and for generating effective tool designs will be developed, perhaps eliminating the need for soft tool tryouts to substantially reduce the total die development time and cost. In this review paper, each of these issues will be discussed.
2007-04-16
Technical Paper
2007-01-0417
Francine Bovard, Janice Tardiff, Tracie Jafolla, Duncan McCune, Greg Courval, Kevin A. Smith, Fred Lee, John Repp, Sridhar Ramamurthy, R. James Shaffer, Florina M. Vartolas
Since 2000, an Aluminum Cosmetic Corrosion task group within the SAE Automotive Corrosion and Protection (ACAP) Committee has existed. The task group has pursued the goal of establishing a standard test method for in-laboratory cosmetic corrosion evaluations of finished aluminum auto body panels. A cooperative program uniting OEM, supplier, and consultants has been created and has been supported in part by USAMP (AMD 309) and the U.S. Department of Energy. Prior to this committee's formation, numerous laboratory corrosion test environments have been used to evaluate the performance of painted aluminum closure panels. However, correlations between these laboratory test results and in-service performance have not been established. Thus, the primary objective of this task group's project was to identify an accelerated laboratory test method that correlates well with in-service performance.
2003-10-27
Technical Paper
2003-01-2749
T. Nakayama, H. Shige, L.F. Vega, E.L. Colvin
Correlation between accelerated laboratory tests and field tests for filiform corrosion of painted aluminum alloy sheets for automobile was investigated by conducting six kinds of laboratory tests with different pH, dry-wet condition, etc., and two sites of outdoor exposure tests, and vehicle test. It was found that susceptibility to filiform corrosion in the laboratory tests increased with the decrease of pH and/or the increase of repetition rate of wet/dry cycle. The susceptibility in the laboratory tests also increased with the increase of Cu contents in the alloy or with the sanding treatment before painting. The same tendency was obtained in the outdoor exposure tests and vehicle test. However, the correlation of the outdoor exposure tests and the vehicle test was low. In conclusion, the laboratory tests with relatively low wet ratio (70%) correlated well with the outdoor exposure tests, and the tests with relatively high wet ratio (95%) correlated well the vehicle tests.
2008-04-14
Journal Article
2008-01-1156
Francine Bovard, Janice Tardiff, Tracie Piscopink-Jafolla, Duncan McCune, Greg Courval, Kevin A. Smith, Fred Lee, Sridhar Ramamurthy, Ray Singleton, Florina M. Vartolas
A task group within the SAE Automotive Corrosion and Protection (ACAP) Committee continues to pursue the goal of establishing a standard test method for in-laboratory cosmetic corrosion evaluations of finished aluminum auto body panels. The program is a cooperative effort with OEM, supplier, and consultant participation and is supported in part by USAMP (AMD 309) and the U.S. Department of Energy. Numerous laboratory corrosion test environments have been used to evaluate the performance of painted aluminum closure panels, but correlations between laboratory test results and in-service performance have not been established. The primary objective of this project is to identify an accelerated laboratory test method that correlates with in-service performance. In this paper the type, extent, and chemical nature of cosmetic corrosion observed in the on-vehicle exposures are compared with those from some of the commonly used laboratory tests
2005-04-11
Technical Paper
2005-01-0542
Francine Bovard, Janice Tardiff, Tracie Jafolla, Duncan McCune, Greg Courval, Kevin A. Smith, Fred Lee, Frank W. Lutze, John Repp
A co-operative program initiated by the Automotive Aluminum Alliance and supported by USAMP continues to pursue the goal of establishing an in-laboratory cosmetic corrosion test for finished aluminum auto body panels that provides a good correlation with in-service performance. The program is organized as a task group within the SAE Automotive Corrosion and Protection (ACAP) Committee. Initially a large reservoir of test materials was established to provide a well-defined and consistent specimen supply for comparing test results. A series of laboratory procedures have been conducted on triplicate samples at separate labs in order to evaluate the reproducibility of the various lab tests. Exposures at OEM test tracks have also been conducted and results of the proving ground tests have been compared to the results in the laboratory tests. Outdoor tests and on-vehicle tests are also in progress. An optical imaging technique is being utilized for evaluation of the corrosion.
2003-03-03
Technical Paper
2003-01-1235
Greg Courval, Kevin A. Smith, Cindy Meade, Frank W. Lutze, Francine Bovard, Tracie Piscopink
The Automotive Aluminum Alliance in conjunction with SAE ACAP founded a corrosion task group in 2000 with a goal to establish an in-laboratory cosmetic corrosion test for finished aluminum auto body panels, which provides a good correlation with in-service performance. Development of this test involves a number of key steps that include: (1) Establishing a reservoir of standard test materials to provide a well-defined and consistent frame of reference for comparing test results; (2) Defining a real-world performance for the reference materials through on-vehicle tests conducted in the U.S. and Canada; (3) Evaluating existing laboratory, proving ground, and outdoor tests; (4) Conducting statistically designed experiments to evaluate the effects of cyclic-test variables; (5) Comparing corrosion mechanisms of laboratory and on-vehicle tests; and (6) Conducting a round robin test program to determine the precision of the new test. Several of these key steps have been accomplished.
2008-08-12
Article
Where there’s a wheel, there could be a way toward a quick and relatively easy reduction in carbon dioxide emissions.
2008-04-25
Article
For the past 30 years, aluminum content per vehicle has grown every year. "I think [in the future] we'll see increased aluminum content in structural chassis parts -- everything from engine cradles to A-pillars, B-pillars, full spaceframes, etc.," said Alcoa's Kevin Kramer. A technology the company is confident will make further inroads is its proprietary Alcoa Vacuum Die Casting.
2015-05-20
Article
A custom tractor-trailer technology demonstrator built by Alcoa is outfitted with various current and “soon-to-be-available” aluminum solutions that altogether can reduce the weight of a tractor-trailer by up to 2500 lb (1135 kg) compared to traditional steel components.
2011-09-22
Article
Alcoa plans a $300 million expansion of its rolled products plant in Davenport, IA, to meet rising demand for automotive aluminum sheet and plate. The project is expected to be completed by the end of 2013.
2009-10-14
Article
The Alcoa fastener conforms to machine-induced micro texture inherent in fastener holes drilled in composite material, reducing the likelihood of electrical arcing in a lightning strike. A paper describing Alcoa’s solution, and the testing that led to it, will be presented at the SAE 2009 AeroTech Congress & Exhibition Nov. 10-12 in Seattle.
2016-07-27
Article
While the cracking debacle on 263 U.S. naval vessels didn’t cause the Navy to halt aluminum use in all ship construction, it did prompt a re-think of future architectures and materials.
2009-07-09
Article
Making a weight saving of 100 kg for a high-performance car is a significant achievement, and that is what Lamborghini has managed for its new Murciélago LP 670-4 SuperVeloce (SV).
2014-01-08
Article
With the world's first pickup featuring an all-aluminum body and cargo box and full LED lighting, Ford leapfrogs its domestic and Japanese competition in the highly profitable full-size truck segment. The structures feature 5xxx- and 6xxx-series alloy sheet, the latter with a T4 temper.
2008-06-30
Article
Several Alcoa-developed high-performance alloys and products produced from its worldwide operations are being used on China’s first home-produced regional jet, the ARJ21-700.
2009-08-05
Article
Alcoa and CIMC Vehicles (Shandong) Co., Ltd., a specialty truck manufacturer in China, have formed a strategic partnership to design and develop a new aluminum fuel tanker trailer for the Asian market.
Viewing 1 to 18 of 18

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