ATZ extra
Advanced aluminum technology for the Automobiles of the Future

The industry
faces challenges

Dear Reader,

Throughout the world today, the automotive industry is required to comply with legislation regarding increasingly strict emissions standards. In particular, the prescribed limits for CO2 emissions have become a major issue for automobile designers. Moreover, electric mobility in all its facets is presenting a challenge for achieving vehicle weight reductions. Solutions are being sought not only in improving engine and exhaust systems, but also in enhancing lightweight design. In this context, aluminum is seen as a progressive means of reducing vehicle weight, while meeting all safety requirements. The percentage of aluminum rolled products used in vehicle construction has been steadily increasing in recent years.

Markus Bereszewski
Chief Editor
Springer Fachmedien Wiesbaden GmbH
Springer nature group
An important factor behind this advance is that aluminum producers, such as Tokyo-based UACJ Corporation, have succeeded in developing advanced aluminum alloys and introducing highly efficient processing technology. UACJ can now boast the world’s third largest production capacity after Arconic and Novelis. Its nearly 300 expert R&D engineers are focusing on the technical development of aluminum alloy products for vehicle weight reduction.

Another very important aspect of the trend is the technology used for joining aluminum components. In addition to conventional joining methods such as riveting, screwing and welding, UACJ has also been perfecting various advanced processes, including Mechanical Clinching, Friction Stir Welding (FSW) and Friction Stir Spot Welding (FSSW). These superior technologies have made it possible to achieve extremely strong joints without the use of rivets. The UACJ R&D team is also working on processes to create secure joints between different materials, such as aluminum and steel or aluminum and resin.

As a result of these research efforts, aluminum alloys are now playing a key role in reducing the weight of both vehicle bodies and chassis structures. This is why luxury SUVs such as the Q7, the luxury AUDI SUV, now feature a frame construction of extruded aluminum components.
COVERSTORY INTERVIEW

"We develop and supply the optimum
materials, together with our customers"

Akio Niikura, Ph. D.
General Manager
Research Development VI
UACJ R&D Division
UACJ Corporation
Sumitomo Light Metal is known globally for the development of Extra-Super-Duralumin (ESD), which laid the foundation of lightweight high-strength material for aircraft. UACJ is a major global aluminum group that was born in Japan in October 2013, when Furukawa-Sky aluminum Corp. and Sumitomo Light Metal Industries Ltd., integrated their business operations. It has the world's third largest production capacity in aluminum rolled products after Arconic and Novelis (as of the 2013 integration date).
The Head Of ce is in Tokyo, Japan, and the R&D Division is in Aichi Prefecture in the central part of Japan. The UACJ Group operates around 85 production and sales bases worldwide, focused on three regions: North America; Europe, including the UK, the Czech Republic and Greece; and Southeast Asia, including China, Thailand and Vietnam.
Akio Niikura received his doctorate at Tohoku University Graduate School in 1995. He belongs to the Institute of Technology Development and has engaged in the research and development of aluminum materials for automobiles for many years. Niikura is currently active at the forefront as a technical manager with automobile manufacturers, especially in North America. He is actively engaged in lecture activities and PR activities at exhibitions of the Society of Automotive Engineers of Japan (JSAE) to further disseminate aluminum materials.

INTERVIEW

What kind of progress have you seen in the development of rolled aluminum products in the last few years?
Against the background of the trend towards reducing vehicle weight, the drastically growing demand for aluminum sheets for the body panels of mass-produced cars. Following customer requests from all over the world, especially North America, where demand is expanding, UACJ has been consolidating its production system to provide high-quality aluminum alloy sheet.

Could you tell us about the R&D Division?
It consists of a group of about 300 expert researchers, the largest number in the world in the rolled aluminum industry. They carry out the development of aluminum alloys and processing technology, analysis technology (simulations), and joining technology, as well as the technological development of surface treatments and production processes.

What kind of research is conducted for the automobile industry?
In the hope of helping to make vehicles lighter in order to reduce CO2 emissions, we’ve been conducting R&D on various automotive materials from every angle in our pursuit of materials with greater strength and excellent formability. The development of processing technology and CAE analysis are, of course, essential for that. Right now, our hottest research theme is joining technologies, such as how to join dissimilar materials and materials with different thicknesses.

What kind of R&D results have you had for automotive materials?
Regarding aluminum alloy sheet for automotive materials, we were one of the first manufacturers in Japan to start working on the development of the 6000 series aluminum alloy sheet for body panels, and we now produce and market aluminum alloy sheet featuring the world’s top level of hemmability. As for extruded products for automotive use, we’ve developed the 7000 series, which displays excellent balance in extrusion performance, strength, weldability and corrosion resistance. Used for bumpers, it greatly contributes to body weight reduction.

How have electric vehicles affected the development of aluminum rolled products?
Electric vehicles feature a compact motor, but they also have to carry large and heavy lithium-ion batteries. That demands a drastic change in the vehicle’s body structure. To match that demand, attention has turned to the use of aluminum extruded materials, and the development of the appropriate utilization technology is underway.

What are the future plans of the UACJ Automotive Materials Research Dept.?
Well, there’s a recent trend towards the use of multi-materials, which means finding the right material for the right application, and the presence of aluminum is growing day by day. Of course, we only have a short history as UACJ, and our company name hasn’t fully penetrated yet, but we’re eagerly moving ahead with the desire to develop and supply the optimum materials for automotive parts together with our customers, based on our world-leading R&D system and our extensive global production and supply system. We will be very happy to hear your requests and ideas. Please contact us at UACJ.