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The influence of additional elements of aluminum alloy, especially of the elements other than conventional low melting point metals on machinability was investigated. Namely, the respective influences of Si, Ni, Mn and Fe on the machinability of AA6061 alloy used as base material were investigated. With the increase in the amount of each element the machinability of the alloy was improved. Si was the most effective among them, and Ni, Mn and Fe followed it in this order. It was found by microscopic observation that machinability was improved in proportion to the dispersion density of the second phase particles formed by the respective additional elements.

The effect of cross-section and type of alloy on the performance of aluminum extrusions as door beams was investigated. As a result, aluminum door beams were developed which have bending properties comparing favorably with those of door beams made of high tensile strength steel with a tensile strength of 1470 N/mm2. Furthermore, a technology to design door beams with the required performance and bending properties dealing with various car models was developed by making the most of the versatility of aluminum extrusions produced in various types of cross-sections.