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2.Makesuretheimageisbehindallobjectsonthepage.Text/colorbars/colorboxes/logos3.DELETETHESEINSTRUCTIONBOXWHENDONE2.Makesuretheimageisbehindallobjectsonthepage.Text/colorbars/colorboxes/logos3.DELETETHESEINSTRUCTIONBOXWHENDONE•October2012FinancialsAutomotiveVS•NovelisAutomiveEuropeMichaelHöhnkeTechnicalSeminarA:GeneralaluminiumandpropertiesSGM-NovelisA.GeneralAluminiumandpropertiesA.1MechanicalpropertiessteelvsaluminiumAluminiumalloysHeat-treatableandnonheat-treatablefamiliesHardeningMechanism5xxx6xxxHeattreatable:precipitationhardeningHardeningduringpaintbakecycleNOYESStrainhardeningHardeningwithdeformation=formingYESYES5xxxalloysLüderslines=notacceptableforskinapplications•Lüderslines(=strecherstrainmarks)aredefectsthatappearduringformingofalloyswithhighMgcontent(like5xxxalloys)AA5182=AlMg4.5Mn0.4AA5754=AlMg3•Thesedefectsarenotacceptableforvisibleparts!TypeALüderslinesTypeBLüderslines5xxxalloysSofteningduringpaintcycle•Duringforming:5xxxalloybecomesstrongerafterforming(strainhardening)•Duringpaintcycle:5xxxalloybecomessoftduetorecovery120140160180200T4150°C20'160°C20'170°C20'180°C20'190°C20'Rp0.2[MPa]AA5182,2%StrainAA5182,5%strainStrain2%Strain5%PaintdryingatcustomerPrecipitationhardeningfor6xxxalloysPaintcuringoven:typicalcycle185°C–20minutes6xxxalloysbecomeharderduringpaintbakecycle=“bakehardening”Comparison5xxxvs6xxxalloysEvolutionofstrengthduringprocessatOEMs6xxxattractiveaslongaspaintbakecycleremainsabove145C20’SurfaceMorphologyIntroductiontoEDTandMF（表面形态-EDT和MF）■EDT(ElectricDischargeTexturing):Rollsurfaceistexturedbymeansofelectricdischarge.Andthetexturetransferstothestripduringrollingpractice.（EDT电火花加工：利用电火花放电对轧制表面进行处理。轧制表面呈条带状。）■Millfinish(MF):Textureafternormalrollingprocess.（MF轧制光面：轧制过程形成的表面纹理。）10SurfaceMorphologyAdvantagesofEDT（EDT表面的优点）■Isotropicstructure（各向同性结构）Improvedlacquerappearanceandpanelmatching（有利于漆与金属表面紧密贴合）Nodirectionalinfluenceontheformingbehavior（变形过程中各向同性）■Lubricationpocketsleadtobuildupofhydrostatic（形成流体静力润滑油储液区）Betterformabilitythanmillfinishsurfaces（成型性优于MF）Improvespress-shophandlingproblemsuchasadoubleblankingduringde-stacking（避免落料分张过程中材料黏结）Lesspick-upofworkpiecematerialonthetoolsurface（避免材料黏结在工具上）Moreconsistentpressparameters（连续冲压）EDTMillFinishSurfaceMorphology3DAnalysisofEDTandMF（EDT和MF的3D分析）EDTislessdirectionalandhasmorepocketsforlubricantthanMF（EDT无各向异性且润滑油聚集孔多于MF）封闭空体体积封闭空体面积比SurfacePretreatmentConversionLayer（表面预处理-转化层）■Longtermstabilityofadhesivebonds（能够长期保持良好的粘着力）■Betteradhesionforadhesives,primersandcoating（更有利于粘合剂，预涂层和涂层与材料之间结合）■Compatibletomostepoxyandrubberbasedadhesives（与大多数环氧基和橡胶基粘合剂兼容）■NonegativeeffectsonthematerialsurfacebehaviorduringZnphosphatingandelectro-coating（对磷化处理和电泳涂装均无不良影响）■Enabletheimplementationofleanprocessforaluminumbodypanels（利于针对铝合金板实行精益生产）基体稳定化预处理13AA6016annealedAA6016acidiccleanedAA6016acidiccleaned+Ti/ZrAssuppliedstateAfter8weeksSCABtestSurfacePretreatmentAdhesionwithadhesive(表面预处理-粘合剂附着力)TensileshearstrengthinMPa拉伸切变强度Surfaceconditionofsheetmaterial材料表面状态退火态退火后酸洗酸洗并镀Ti/Zr（8周疤痕腐蚀试验后）（供货状态）LubricantsIntroduction（润滑剂）■Solidtypelubricants（固体润滑剂）Water-solubledryfilmlubricantsandwater-freedryfilmlubricants(Hotmelts)areavailable.（可溶于水的干膜润滑剂和防水的热熔性干膜润滑剂均可选用）Water-solubledryfilmlubricants:Waterbasedlubricants,thewaterneedstobedriedaftersprayonthealuminumsurface.（可溶于水的干膜润滑剂：水基润滑剂，喷涂在铝合金表面后，将水分干燥除去）Water-freedryfilmlubricants(Hotmelts):Thelubricatedisheatedupandbecomeliquid.Afterthencooleddownincontactwiththealuminumsurface.（防水热熔性干膜润滑剂:将润滑剂加热至液态后涂于铝合金表面）■Oilbasedliquidlubricants（油基液态润滑剂）Usedforsurfaceprotection(toavoidscratchduringstackingandtransport)（用于表面保护，避免堆垛和运输过程中划伤表面）Thecustomermustperformre-oilingfordeepdrawing（深冲前必须再次进行预涂油）15LubricantsAdvantageofdryfilmlubricants（干膜润滑剂的优点）■Betterformability（利于材料成型）■Largerprocesswindowsbecauseoflowfrictioncoefficients（低摩擦系数，工艺参数选择空间大）(冲压深度mm)(压边力N)LubricantsAdvantageofdryfilmlubricants.（干膜润滑剂的优点）■Betterdestackingandsurfaceprotection（便于分张及保护产品表面）■Uniformcoatingthicknessandnorunoff（厚度均匀且不会流失）油基液态润滑剂干膜润滑剂清洗-油量1.5g/m2-局部不均匀-润滑剂流失涂油-点状涂油-油量1.0±0.5g/m2-润滑剂流失再次清洗-润滑油量过大不利于装配轧制时进行清洗和涂油-工艺过程更稳定-润滑油量适用于粘接过程无需进行再次清洗-装配过程前无需除油采用2D或3D技术测定润滑剂量及表面形态LubricantsAdvantageofdryfilmlubricants（干膜润滑剂的优点）■Goodcorrosionprotection（良好的防腐性能）■Nore-oilingbeforehemmingandmechanicaljoiningprocess（卷边和机械连接前无需预涂油）■CompatibletoECpaintline（适用于电泳涂装生产线）■Compatibilitywithassemblyoperations(adhesive,welding,bonding,clinching,andriveting)（适用于装配过程）A.2Mainissueswhenusingaluminium19UseofaluminiumpanelsRequirementsforautomotiveapplications1.Specialrequirementsforaluminiuminautomotiveapplications2.Logistici.naturalageingii.transport3.SpecifictoOEMs1.RequirementsforaluminiumuseinautomotiveExample1:motorhood•Highstrength:downgauging,stoneimpact•Bendability:hemming(assembly)•Formability:design•Energyabsorption:pedestriansafety•Surfacequality:largeflatvisiblesurfaceRopehemFlathem1.RequirementsforaluminiumuseinautomotiveExample2:doorinnerpanel•Weldability:frameassembly•Highformability:deepdrawing•Corrosionresistance222.LogisticconsiderationNat