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The MMLV lightweight body features eight aluminum castings that were produced via high pressure vacuum diecasting.


MMLV轻量化车身包含使用真空压铸 工艺生产的8个铝合金铸件。


aluminum and 35% steel. Te MMLV BIW, Closure panels and Chassis subsystems are comprised of aluminum extru- sions, die castings and stampings along with stamped steel fabrications. Te baseline Fusion BIW was 100% steel. In the MMLV, steel was placed in areas where require-


ments for energy absorption for side impact, roof crushing and frontal impact protection were high. Aluminum was placed around the steel—such as in the major panels, which were not structural. For areas that were structural, Magna utilized aluminum high pressure vacuum die castings. “Aluminum castings were integral to the design, and


they were strategically placed for both stiffness and strength requirements,” said Jeff Conklin, engineering department manager, Cosma International, the metalforming division of Magna. “If we had used other processes, we wouldn’t have the stiffness and the weight reduction wouldn’t have been as significant.”


One of the objectives of the MMLV was that it would meet the same five-star occupant safety ratings as the consumer version of the Ford Fusion. Te actual MMLV concept car was physically put through a limited number of front impact safety tests from the U.S. New Car Assessment Program (NCAP) and the Insurance Institute for Highway Safety (IIHS) and passed them without trouble.


Castings’ Role Te MMLV lightweight body features eight alumi-


num castings that were produced via high pressure vacuum diecasting. Te use of high pressure vacuum diecasting is unique for high volume automotive production, but the pro- cess allowed engineers to design castings for structural areas of the vehicle. “When the castings are used as a structural part, they must


carry the load during a crash event,” Conklin said. “High pressure vacuum diecasting gives three times the ductility of conventional diecasting, which opens up a new market.” Making the parts in a vacuum gives producers the ability to heat treat without causing blistering or trapped gas. Tese


公司设计了采用双金属的白色车身(BIW),由65%的铝 合金和35%的钢组成。MMLV BIW,覆盖板和底盘子 系统由铝合金挤压件、压铸件和冲压件以及冲压钢结构 组成。基准的福星汽车白车身使用的材料是100%的合 金钢。


在MMLV项目中,在侧面碰撞、车顶粉碎和正面碰 撞对于能量吸收要求高的位置使用了合金钢。在合金钢 周边使用了铝合金,例如非结构件的主覆盖板。对于结 构件部分,Magna公司采用了铝合金真空压铸件。 “铝合金铸件对于整体设计是必不可少的一部分,它 们对于硬度和强度要求起到战略性的作用,”Magna 公司的金属成形部Cosma国际公司工程部经理Jeff Conklin说:“如果我们采用其他的工艺,我们将不可 能获得这样的刚性,而且重量也不会减轻这么多。” MMLV的一个目标是达到福特福星商务款汽车的五 星驾驶安全等级。目前,MMLV的概念车已在物理上进 行了美国新车安全测试评估方案(NCAP)和公路安全 保险协会实施的少数正面碰撞安全测试,并且安全通过 测试。


铸件的作用


MMLV轻量化车身包含使用真空压铸工艺生产的8个 铝合金铸件。在大批量的汽车制造中使用真空压铸件是 独一无二的,这是因为从技术上允许工程师在汽车结构 件领域设计中使用压铸件。


“当铸件作为结构件使用时,它们必须能够在碰撞 发生的情况下承重,”Conklin说:“真空压铸件的延 展性是传统压铸件的3倍,因此,为真空压铸件打开了 新的市场。”


50 | FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION December 2015


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