Page 4 - Mortor Fan illustrated

ALUMINUM Smart Developments

Case Study Aluminum technologies for the new LS

02 02 LEXUS LS

Motor Fan illustrated
Motor Fan illustrated

ALUMINUM Smart Developments

04 The new LS has the latest structure that uses a considerable Other carmakers produce inner panels in three parts, but the ALUMINUM Smart Developments
05
amount of aluminum alloy in the outer panels, and ultra-high
LS panels are formed as single pieces. This is largely a result of
tensile strength steel in the frame. In addition to the bonnet, Toyota’s excellent stamping technology, with aluminum
trunk lid and front fender aluminum is used for the doors. The manufacturer UACJ’s backstage support.
application of aluminum has reduced the total body weight by
25% compared to the previous all-steel model, and because Spring-back emerges as a problem when considering changing
the car has four doors, there is an even greater effect on weight to one-piece aluminum inner door panels, because of its
reduction. inferior formability and shape-freezing properties. Most
European carmakers have stamping lines with five to six
In general, the inner door panel has a complicated structure, so processes, but Japanese carmakers have production facilities LS500
5000 series alloys are frequently used because of their high with four processes. One drawing process is sufficient for steel,
formability. In consideration of dent resistance, 6000 series but aluminum requires two. This means that other processing For the new LS body,
alloys are used for the outer door panels. However, Toyota has to be carried out by the remaining two processes. The aluminum alloys are used for
decided to use 6000 series for both the inner and outer panels high-level stamping technology which forms aluminum in four the bonnet, trunk lid, front
of the new LS. processes has been developed by Toyota Motor. fender, suspension tower,
bumper beams and doors.

Hiroaki Hashiya Tatsuya Higuchi Tohru Hioki

Assistant Manager Assistant Manager Assistant Manager
MS Vehicle Quality & Production Production Preparation Dept., MS Stamping Production Engineering Div.,
Engineering Div., Lexus Management Div., Mid-size Vehicle Company,
Mid-size Vehicle Company, Toyota Motor Corporation Toyota Motor Corporation
Toyota Motor Corporation
Aluminum
High-tensile steel
(Motorfan Illustrated Vol.138)

PHOTO: LEXUS