Aluminum Application in Automotive Industry and What is Aluminum Alloys

We shall discuss the aluminum application in the automotive industry and what is aluminum alloys.

as manufacturers look to the future, automation is undoubtedly one of the key technologies changing the way the industry works. From the artificial intelligence revolution to self-driving cars to robotic production lines, automation connects these disparate provinces. Aluminum and many high-performance alloys are important factors in all types of automation.

However, few people realize that aluminum is the material of the future. Aluminum seems to have been around for a long time, but it has only been a viable commercial material for less than 100 years.

Aluminum is one of the most common materials on earth due to its high reactivity and ease of combining with other elements to form ores and minerals. Chemists have spent decades developing an easy way to extract and separate aluminum for industrial use.

Not all automation involves robots. Although many people only think about robotics when they think of automation, it includes much more. Any technology that enables a task to be completed with little to no human interaction is referred to as automation.

It is sometimes referred to as automated control and normally comprises of a control system that may take the place of human operators in anything from operating heavy machinery to piloting an airplane. Thermostats are one of the most basic and oldest examples of automation.

Instead of manually measuring and adjusting temperatures, thermostats automatically read, adjust, or turn heating or cooling equipment on and off at predetermined thresholds. On the other hand, large industrial control systems may contain thousands or tens of thousands of input and control output signals. Modern automation techniques may rely on several complex algorithms to evaluate and respond to any given situation.

An automated system consists of several different components. It requires a data input device that measures or evaluates the external environment, which may include various thermometers, cameras, vibration sensors, radar, infrared devices, and more.

Then the system must have control system to perform the desired function. Traditionally, automation has been achieved mechanically, hydraulically, pneumatically, electrically, or digitally.

Since then, Application of aluminum in automation in today’s economy, a problem common to all manufacturing interests is labor shortages. Since unemployment is low in many industrial areas, automating as many processes as possible is a fundamental solution to this labor problem.

Robot-assisted processes require precision and tight tolerances when measuring, gripping, and placing workpieces.

It requires stress-free base plates for automated equipment that are machined to close tolerances to avoid dimensional drift during manufacturing.

For these applications, steel can be used, but most carbon steel products must be stress relieved after fabrication and then milled or machined to final size.

These benefits are provided by aluminum casting tools and fixture plates, which eliminate multiple processes for manufacturing substrates and fixtures. T-slot aluminum profiles are useful in designing automation systems.

Custom-sized frames for automated workstation safety barriers can be easily and cost-effectively installed using these extrusions, and enclosures can be finished with plexiglass, wire mesh, or sheet metal. Which aluminum alloys are commonly used in automation applications? Most T-slot extrusions and custom extrusions are made from 6063, but many customers specify 6061 or 6005 depending on the application.

Base plates for mechanized automation equipment, robotics, measuring and sensing instruments, jigs, and fixtures can be made from heat-treatable grades such as 6061, but are typically designed with casting tooling and jig plate specifications.

For these applications, the modified 5083 has become a popular grade in the industry, but 7XXX series variants are also widely used in the market.

Performance benefits: Depending on the product, aluminum is typically 10% to 40% lighter than steel. Aluminum cars have better acceleration, braking and handling. The hardness of aluminum allows the driver to take control faster and more efficiently.

Aluminum forging enables designers to create automotive designs optimized for maximum performance. Safety advantage: In the event of an accident, aluminum absorbs twice as much energy as steel of the same weight.

Environmental benefits: More than 90% of automotive aluminum waste is recovered and recycled. 1 ton of recycled aluminum is equivalent to energy savings of 21 barrels of oil. Compared to steel, using aluminum in car manufacturing can reduce life cycle CO2 emissions by 20%. A

ccording to Alcoa’s report, The Elements of Sustainability, replacing the steel fleet with aluminum vehicles could save 108 million barrels of crude oil and prevent 44 million tons of carbon dioxide emissions.

Fuel efficiency: Aluminum alloy cars are 24% lighter than steel cars. This results in fuel savings of 0.7 gallons per 100 miles, or 15 percent less energy consumption than steel vehicles.

Similar fuel savings can be achieved when aluminum is used in hybrid, diesel, and electric vehicles. Durability: Vehicles with aluminum components last longer and require less maintenance against corrosion.

Aluminum parts are suitable for vehicles that work in extreme environmental conditions such as off-road and military vehicles. What sets aluminum apart from other metals A very light metal, aluminum.

It is only one-third as dense as steel. Aluminum has high strength compared to other materials. Aluminum alloys have a tensile strength between 70 and 700 MPa.

Unlike steel, aluminum does not break easily at low temperatures. In fact, the toughness of aluminum increases with decreasing temperature.

Flexibility: Aluminum’s strength combined with its flexibility means it can bend under pressure and spring back under impact. Malleability: Aluminum is a very flexible metal that can be extruded through a mold into any desired shape. Aluminum can be cold extruded or hot extruded.

Bending and shaping techniques can be used for further modification. Aluminum has high thermal and electrical conductivity.

Aluminum conductors weigh about half the weight of similar copper conductors with the same conductivity. Reflection: Aluminum is a good reflector of heat and light.

Corrosion resistance: Aluminum combines with oxygen in the air and forms a thin layer of oxide. Although this layer is only 4 nm thick, it has good corrosion resistance. If damaged, it can even heal on its own.


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