Christopher S. Young

Overview of superplastic forming research at ford motor company

In an effort to reduce vehicle weight, the automotive industry has switched to aluminum sheet for many closure panels. Although the application of aluminum is compatible with existing manufacturing processes and has attractive qualities such as low density, good mechanical properties, and high corrosion resistance, it has less room-temperature formability than steel. The expanded forming limits that are possible with superplastic forming can significantly improve the ability to manufacture complex shapes from materials with limited formability. Aluminum closure panels produced by superplastic forming have been used by Ford Motor Company for over a decade. However, applications have been limited to low-volume, specialty vehicles due to the relatively slow cycle time and the cost penalty associated with the specially processed sheet alloys. While there has been substantial research on the superplastic characteristics of aluminum alloys, the bulk of this work has focused on the development of aerospace alloys, which are often too costly and perhaps inappropriate for automotive applications. Additionally, there has been a limited amount of work done to develop the technologies required to support the higher production volumes of the automotive industry. This work presents an automotive perspective on superplastic forming and an overview of the research being performed at Ford Motor Company to increase the production volume so superplastic forming can be cost competitive with more traditional forming technologies.

The P2000S Unitized Sport Utility Vehicle Body Structure

The P2000S body structure was designed as part of an advanced research project to determine the feasibility of a high volume, lightweight sport utility vehicle (SUV) that would achieve performance targets of the newly emerging City SUV market by developing a unitized (no frame) SUV body structure fabricated principally of aluminum. In order to be viable, this body structure was required to meet all safety, durability, NVH and other functional attributes of a truck while having the ride characteristics of a sedan. This paper describes the P2000S body structure including the structural philosophy, project constraints on the design, manufacturing processes, supporting analyses, assembly processes and unique material and design concepts which resulted in the 50% body structure weight reduction in comparison to similar sized body-on-frame production steel sport utility vehicles.

A Design Concept for an Aluminum Sport Utility Vehicle Frame

As part of the joint government/industry Partnership for a New Generation Vehicle (PNGV), Ford Motor Company, with the support of Alcan Aluminum Corporation and The Budd Company, conducted a feasibility study of the design and high volume manufacturing of a lightweight aluminum sport utility vehicle frame. The specific objective of the study was to assess the capability of an aluminum frame to achieve equivalent performance to the 2002 Ford Explorer frame, but at a 40% weight reduction. Using Finite Element Analysis (FEA), it was determined that if a design was constrained to the same section size as the production steel frame, the maximum weight savings that can be realized by use of aluminum is approximately 20%. However, if the side rail sections between the front and rear suspension points can be modestly increased, the aluminum frame can match the production steel frame in static bending and torsional stiffness and have greater normal mode frequencies than the production steel frame. In addition, this allows for an approximate 40% reduction in weight compared to the production steel frame. Preliminary analysis also indicates an aluminum frame with the gage required to achieve the desired stiffness needed for ride, handling and NVH (noise, vibration and harshness) will probably have excellent energy absorption during frontal impacts.