Automotive lightweight

1. Thermoforming

The thermoforming has high precision and good forming performance, and is widely used in the production of high-strength automobile bumpers, door anti-collision bars, A, B, C pillar reinforcements, roof frames, middle passages and other safety parts and structural parts. At present, GM, Ford, Germany Volkswagen and China FAW Hongqi H7 are using this technology to manufacture high-strength stampings.

Figure 1 Examples of application of thermoforming technology on the underbody of Hongqi H7

2. Laser welding

In 1985, Audi successfully adopted the world's first laser tailored blank. In the 1990s, major auto companies in Europe, America and Japan began to use laser tailor welding technology on a large scale. In recent years, this technology has been widely used in the design and manufacture of new types of steel body in the world. The FAW Hongqi H7 body also uses laser welding for typical structural parts.

 (a) Front longitudinal beam                  (b) Front floor

Figure 2 Typical structural parts using laser tailoring technology on the body of Hongqi H7 car

3. Tailor rolled blanks

The tailor rolled blanks appeared after the laser welding to solve the problems of the laser tailor-welded plate. Tailor rolled blanks can replace laser tailor-welded plates, so as to achieve lighter weight. However, it cannot completely replace the laser tailor-welded plate, because in addition to welding sheets of different thickness, the laser tailor-welded plate can also weld plates of different materials and strengths together, and tailor rolled blanks cannot achieve this function. The production process is shown in the figure.

Fig. 3 Diagram of the production process of tailor rolled blanks

4. Lock riveting connection technology

The lock riveting connection technology has the characteristics of no pre-punching before connection, simple process steps, high production efficiency, etc., which makes it very large in connecting light materials such as aluminum alloy, magnesium alloy and dissimilar materials or plated materials on the surface. Advantages, occupy a very important position in the connection of car bodies.

Figure 4 Locking riveting connection technology route

5. Hydroforming

Hydroforming, also known as internal high pressure forming, is especially suitable for the production of large plate parts with complex shapes, variable dimensions, high appearance quality requirements, and small batches. It simplifies and flexibly produces complex shape plate parts and realizes rapid parts. Manufacturing, and greatly reduce mold costs

Figure 5 Example of internal high-pressure sheet forming