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 reserved
No part of this publication may be reproduced in any material form (including photocopying or
storing in any medium by electronic means and whether or not transiently or incidentally to some
other use of this publication) without the written permission of the copyright holder except in
accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms
of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London,
England W1T 4LP. Applications for the copyright holder’s written permission to reproduce any part
of this publication should be addressed to the publisher
Permissions may be sought directly from Elsevier’s Science and Technology Rights
Department in Oxford, UK: phone: (+44) (0) 1865 843830; fax: (+44) (0) 1865 853333;
e-mail: permissions(собачка)elsevier.co.uk. You may also complete your request on-line via the
Elsevier homepage (http://www.elsevier.com), by selecting ‘Customer Support’
and then ‘Obtaining Permissions’
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloguing in Publication Data
A catalogue record for this book is available from the Library of Congress
ISBN 0 7506 5692 1
For information on all Butterworth-Heinemann
publications visit our website at www.bh.com
Typeset by Replika Press Pvt Ltd, India
Printed and bound in Great Britain
Contents
Preface vii
Acknowledgements ix
About the author xi
Disclaimer xiii
1 Introduction 1
1.1 Overview of content 1
1.2 Materials overview 1
1.3 General format of presentation 5
1.4 Introduction to body architecture and terminology 7
2 Design and material utilization 10
2.1 Introduction 10
2.2 Historical perspective and evolving materials technology 11
2.3 Finite element analysis 18
2.4 One manufacturer’s approach to current design 22
2.5 Panel dent resistance and stiffness testing 29
2.6 Fatigue 32
2.7 Alteative body architecture 35
2.8 Integration of materials into designs 45
2.9 Engineering requirements for plastic and composite components 55
2.10 Cost analysis 56
2.11 Leaing points from Chapter 2 59
3 Materials for consideration and use in automotive body structures 61
3.1 Introduction 61
3.2 Material candidates and selection criteria 65
3.3 Aluminium 87
3.4 Magnesium 91
3.5 Polymers and composites 92
3.6 Leaing points from Chapter 3 97
4 The role of demonstration, concept and competition cars 99
4.1 Introduction 99
4.2 The BL Energy Conservation Vehicle (ECV 3) and aluminium
structured vehicle technology (ASVT) 100
4.3 ULSAB and ULSAB 40 105
4.4 Concept cars 108
4.5 Competition cars 111
4.6 Key leaing points from Chapter 4 128
5 Component manufacture 130
5.1 Steel formability 130
5.2 Aluminium formability 146
5.3 Manufacture of components in magnesium 158
5.4 Production of polymer parts 158
5.5 Leaing points from Chapter 5 166
6 Component assembly: materials joining technology 170
6.1 Introduction 170
6.2 Welding 170
6.3 Adhesive bonding 183
6.4 Mechanical fastening 185
6.5 Leaing points from Chapter 6 186
7 Corrosion and protection of the automotive structure 189
7.1 Introduction 189
7.2 Relevant corrosion processes 190
7.3 Effective design principles 194
7.4 Materials used for protection of the body structure 196
7.5 Empirical vehicle and laboratory comparisons 209
7.6 An introduction to electrochemical methods 210
7.7 Leaing points from Chapter 7 216
8 Environmental considerations 220
8.1 Introduction 220
8.2 Effect of body mass and emissions control 221
8.3 Life cycle analysis (LCA) 224
8.4 Recycling and ELV considerations 228
8.5 Hygiene 237
8.6 BIW design for safety 239
8.7 Leaing points from Chapter 8 249
9 Future trends in automotive body materials 252
9.1 Introduction 252
9.2 Factors influencing material change in the future – trends and
requirements 253
9.3 Combined effect of above factors on materials utilization within
‘expected’ and ‘accelerated’ timescales 262
9.4 Leaing points from Chapter 9 268
Index 271
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 reserved
No part of this publication may be reproduced in any material form (including photocopying or
storing in any medium by electronic means and whether or not transiently or incidentally to some
other use of this publication) without the written permission of the copyright holder except in
accordance with the provisions of the Copyright, Designs and Patents Act 1988 or under the terms
of a licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham Court Road, London,
England W1T 4LP. Applications for the copyright holder’s written permission to reproduce any part
of this publication should be addressed to the publisher
Permissions may be sought directly from Elsevier’s Science and Technology Rights
Department in Oxford, UK: phone: (+44) (0) 1865 843830; fax: (+44) (0) 1865 853333;
e-mail: permissions(собачка)elsevier.co.uk. You may also complete your request on-line via the
Elsevier homepage (http://www.elsevier.com), by selecting ‘Customer Support’
and then ‘Obtaining Permissions’
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
Library of Congress Cataloguing in Publication Data
A catalogue record for this book is available from the Library of Congress
ISBN 0 7506 5692 1
For information on all Butterworth-Heinemann
publications visit our website at www.bh.com
Typeset by Replika Press Pvt Ltd, India
Printed and bound in Great Britain
Contents
Preface vii
Acknowledgements ix
About the author xi
Disclaimer xiii
1 Introduction 1
1.1 Overview of content 1
1.2 Materials overview 1
1.3 General format of presentation 5
1.4 Introduction to body architecture and terminology 7
2 Design and material utilization 10
2.1 Introduction 10
2.2 Historical perspective and evolving materials technology 11
2.3 Finite element analysis 18
2.4 One manufacturer’s approach to current design 22
2.5 Panel dent resistance and stiffness testing 29
2.6 Fatigue 32
2.7 Alteative body architecture 35
2.8 Integration of materials into designs 45
2.9 Engineering requirements for plastic and composite components 55
2.10 Cost analysis 56
2.11 Leaing points from Chapter 2 59
3 Materials for consideration and use in automotive body structures 61
3.1 Introduction 61
3.2 Material candidates and selection criteria 65
3.3 Aluminium 87
3.4 Magnesium 91
3.5 Polymers and composites 92
3.6 Leaing points from Chapter 3 97
4 The role of demonstration, concept and competition cars 99
4.1 Introduction 99
4.2 The BL Energy Conservation Vehicle (ECV 3) and aluminium
structured vehicle technology (ASVT) 100
4.3 ULSAB and ULSAB 40 105
4.4 Concept cars 108
4.5 Competition cars 111
4.6 Key leaing points from Chapter 4 128
5 Component manufacture 130
5.1 Steel formability 130
5.2 Aluminium formability 146
5.3 Manufacture of components in magnesium 158
5.4 Production of polymer parts 158
5.5 Leaing points from Chapter 5 166
6 Component assembly: materials joining technology 170
6.1 Introduction 170
6.2 Welding 170
6.3 Adhesive bonding 183
6.4 Mechanical fastening 185
6.5 Leaing points from Chapter 6 186
7 Corrosion and protection of the automotive structure 189
7.1 Introduction 189
7.2 Relevant corrosion processes 190
7.3 Effective design principles 194
7.4 Materials used for protection of the body structure 196
7.5 Empirical vehicle and laboratory comparisons 209
7.6 An introduction to electrochemical methods 210
7.7 Leaing points from Chapter 7 216
8 Environmental considerations 220
8.1 Introduction 220
8.2 Effect of body mass and emissions control 221
8.3 Life cycle analysis (LCA) 224
8.4 Recycling and ELV considerations 228
8.5 Hygiene 237
8.6 BIW design for safety 239
8.7 Leaing points from Chapter 8 249
9 Future trends in automotive body materials 252
9.1 Introduction 252
9.2 Factors influencing material change in the future – trends and
requirements 253
9.3 Combined effect of above factors on materials utilization within
‘expected’ and ‘accelerated’ timescales 262
9.4 Leaing points from Chapter 9 268
Index 271