Experimental Characterization of Aluminum Alloys for the Automotive Industry 2022-36-0031

Several factors stimulate the development of new materials in the industry. From specific physical-chemical characteristics to strategic market advantages, technology companies seek to diversify their raw materials. In the automotive sector, the current trend of electrification in vehicles and the increase of government and market demand for reducing the emission of greenhouse gases makes lighter materials more and more necessary. As electric vehicles use heavy batteries, the vehicle weight is directly related to its power demand and level of autonomy. The same applies to internal combustion vehicles where the vehicle weight directly impacts fuel consumption and emissions. In this context, there is a lot of research on special alloys and composites to replace traditional materials. Aluminum is a good alternative to steel due to its density which is almost five times smaller while that material still has good mechanical properties and has better impact absorption capability. This work focuses on the development of a 5XXX series aluminum alloy for body and closures panels. Experimental characterization of aluminum alloy 5052-O and 5052-H32 was carried out in order to obtain input data for future Computed-aided Engineering (CAE) tests to check suitability in drawing process. A tensile test was carried out to obtain the true stress-strain curve using an EMIC 5000, and a Nakazima test was carried out to determine the Forming Limit Curve using an Erichssen 142-20 testing machine. Both alloys presented good mechanical and formability properties, however, 5052-O was more suitable for deep stamping applications.