Grant: Automotive Partnership Canada Project

This project will address the design and optimization, material selection and texture development, and manufacturing ofa one-piece extruded front rail intended for mass production within mid-size cars, such as the Chevrolet Malibu,Chevrolet Impala and Buick Regal after 2017. Apart from the one-piece front rail, other outcomes include: a completefront rail design optimization that maximizes energy absorption characteristics and a new aluminum alloy that is not onlyperfect for extrusion, but demonstrates superior energy absorption and strength characteristics.This proposal is built around three highly integrated themes: (1) front rail design for optimized weight reduction andperformance, (2) aluminum alloy development, and (3) simplified manufacturing process development.Optimized front rail design: The front rail geometry and material will be optimized for maximum performance and weightreduction. This will be achieved by increasing the energy absorption per unit mass (to improve performance) andshortening the length (weight reduction) of the front rail. Front rail lengths of less than O.Bm and a total weight reductionof 30-40% (in the front rail; compared to steel) are targeted.Alloy development: Based on the properties of 'pilot' alloy AA6063, an aluminum alloy will be developed with strengthand energy absorption characteristics that are comparable to conventional steels. Once developed, several tests, suchas tension, bending, compression, dome, biaxial stress tests, as well as microstructural studies using electronmicroscopy will be performed to characterize mechanical and physical properties of the developed alloy.Simplified manufacturing process: Extrusions, which are much more cost efficient than complex assemblies with multiplestampings, will be used to fabricate the new rails.Ultimately, this project will address the design and optimization, material selection and texture development, andmanufacturing of a one-piece extruded front rail intended for mass production within mid-size cars, such as theChevrolet Malibu, Chevrolet Impala and Buick Regal after 2017. Apart from the one-piece front rail, other outcomesinclude: a complete front rail design optimization that maximizes energy absorption characteristics and a new aluminumalloy that is not only perfect for extrusion, but demonstrates superior energy absorption and strength characteristics.