Aluminum Body 2
In the aluminium car body production there are parts which can not be produced by using customary manufacturing processes. Aluminium die casting, e.g., reduces the number of total parts, makes repairing easier
and in addition, allows very precise working.
How it works
The above picture shows a B pillar which was produced in one piece. Whereby, in this case, the mounting connections are already integrated. In the (vacuum) die casting process even the production of screw-
threading is possible. Either the doors can be mounted here directly, or the door hinges can be screwed on. Additional operations would be necessary in case the B pillar would have been made from sheet metal.
The frame of the car body consists primarily of profile-beams which are connected to each other by aluminium castings. The nodular points are concave inside and provided with strengthening ribbing. This technology
is being used more and more often. e.g., in producing cylinder blocks which are strongly ribbed, particularly in the area of the crankshaft. One gains more
stability with less material.
Computers calculate exactly at which point force is applied from a driving- or chassis part to this nodule, which is then precisely strengthened there (finite element method).
Not only must the passenger cell be
stable, also the rear- and particularly the front-end must be only partially deformable e.g., bumpers and main chassis beams must be able to go through certain, exactly agreed crash speeds without distortion. Should
these parts, however, become damaged, repair work should be possible without welding being necessary. Disregarding this could mean higher insurance premiums for the customer. 07/08