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International Journal of Material Forming

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08-01-2021 | Original Research

Numerical modeling of mechanical properties of UAM reinforced aluminum hat sections for automotive applications

Authors: Hyunchul Ahn, M. Bryant Gingerich, Ryan Hahnlen, Marcelo J. Dapino, Farhang Pourboghrat

Published in: International Journal of Material Forming | Issue 5/2021

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Abstract

Structural lightweighting is a key initiative in the automotive sector due to regulatory, customer, and powertrain demands. This research focuses on reinforcing aluminum sheet metal in strategic locations using ultrasonic additive manufacturing (UAM), as guided through an iterative optimization and simulation process. Among the three models used, the most successful is the multi-step model (MSM) which simulates the forming of tailored blanks and the unloading processes to accurately map the hardening and the residual stress in hat and reinforcement sections. The MSM shows that approximately 65% of the mass can be saved by replacing a large gauged sheet metal hat section with a discretely reinforced hat section. Further increases in specific energy absorption (SEA) and additional mass savings can be expected when utilizing higher specific strength and specific stiffness materials for reinforcement such as titanium alloys, composites, or ceramic materials, all of which have been demonstrated with UAM.

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Title: Numerical modeling of mechanical properties of UAM reinforced aluminum hat sections for automotive applications
Authors: Hyunchul Ahn
M. Bryant Gingerich
Ryan Hahnlen
Marcelo J. Dapino
Farhang Pourboghrat
Publication date: 08-01-2021
Publisher: Springer Paris
Published in: International Journal of Material Forming / Issue 5/2021
Print ISSN: 1960-6206
Electronic ISSN: 1960-6214
DOI: https://doi.org/10.1007/s12289-020-01607-3

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