And the use of aluminum in the production of a body seems so seductive and new technology that it is forgotten that it comes from the first half of the twentieth century. As a constructive material for cars, it was tested immediately, as soon as they began to abandon wood and leather, and it turned out to be so well compatible with wood that this technology is still used on Morgan cars. That's just the majority of companies that in the thirties managed to produce a lot of cars with the widespread use of aluminum parts, later abandoned light metal. And the reason was not only the shortage of this material during the Second World War. The plans of science fiction futurists about the widespread use of aluminum in the design of machines were not destined to come true. In any case, until now, when something began to change.
Aluminum in metal form has not been known for so long - it was brought out only at the end of the 19th century, and it immediately began to be highly valued. And not at all because of its rarity, just before the discovery of the electrolytic reduction method, production was fabulously expensive, aluminum was more expensive than gold and platinum. No wonder the scales presented to Mendeleev after the discovery of the periodic law contained many aluminum parts; at that time it was a truly royal gift. From 1855 to 1890, only 200 tons of material were produced according to the Henri-Étienne Saint-Clair Deville method, which consists in displacing aluminum with sodium metal.
1 / 3
2 / 3
3 / 3
Already by 1890, the price had fallen 30 times, and by the beginning of the First World War - more than a hundred. And after the thirties, it constantly maintained approximate parity with the prices of rolled steel, being 3-4 times more expensive. The shortage of certain materials periodically changed this ratio for a short time, but nevertheless, on average, a ton of aluminum always costs at least three times more than ordinary steel.
"Winged" aluminum is called for a combination of low weight, strength and affordability. This metal is noticeably lighter than steel, accounting for approximately 2,700 kg per cubic meter versus 7,800 kg for typical steel grades. But the strength is also lower, for common grades of steel and aluminum, the difference is about one and a half to two times both in terms of fluidity and tension. If about specific figures, then the strength of the aluminum alloy AMg3 is 120/230 MPa, low-carbon steel grade 2C10 is 175/315, but high-strength steel HC260BD is already 240/450 MPa.
As a result, aluminum structures have every chance of being noticeably lighter, at least by a third, but in some cases, the superiority in the mass of parts can be greater, because aluminum parts have higher rigidity and are noticeably more technologically advanced to manufacture. For aviation, this is a real gift, because more durable titanium alloys are much more expensive, and mass production is simply not available, and magnesium alloys are highly corrosive and highly flammable.
Practice on the ground
In the mass consciousness, aluminum bodies are mainly associated with cars. brand Audi, although the first in the back of the D2 appeared only in 1994. It was one of the first large-scale integral aluminum machines, although a fair amount of winged metal was a trademark of such brands as Land Rover And Aston Martin for decades, not to mention the already mentioned Morgan, with its aluminum on a wooden frame. Still, advertising works wonders.
1 / 4
2 / 4
3 / 4
4 / 4
First of all in new technology body manufacturing emphasized the low weight and resistance of aluminum bodies to corrosion. Other advantages of aluminum structures were sometimes mentioned: for example, the special acoustic properties of bodies and the passive safety of forged and cast structures.
List of cars in which aluminum parts make up at least 60% of the body mass (not to be confused with gross weight cars) is quite large. First of all known Audi models, A2, A8, R8 and related R8 Lamborghini Gallardo. Less obvious are the Ferrari F430, F360, 612, the latest generations of the Jaguar XJ X350-X351, XJR, XF, XE and F-Pace. connoisseurs of real sports cars remember the Lotus Elise, as well as the platform Opel Speedster and Tesla roadster. Especially meticulous readers will remember Honda NSX, Spyker and even Mercedes SLS.
Photo: Audi A2 aluminum space frame
It is often mistaken to classify modern Land Rover as aluminum, range rover, BMW latest series and some other premium models, but there the total share of aluminum parts is not so large, and the body frame is still made of steel - ordinary and high strength. There are few all-aluminum machines, and most of them are relatively small-scale designs.
But how is it? Why, with all its advantages, aluminum is not used as widely as possible in the body structure?
It would seem that you can win on the mass, and the difference in the price of materials is not so critical against the background of other components of the cost of an expensive car. A ton of "winged" now costs $ 1,600 - this is not so much, especially for a premium car. Everything has an explanation. True, to understand the issue again, you have to go a little deeper into the past.
How aluminum lost to plastic and steel
The eighties of the twentieth century will go down in the history of the automotive industry as a time when the main brands in the world market were formed and a balance of power was created that has changed little to this day. New blood has since been added automotive market only Chinese companies, otherwise, it was then that the main trends, classes and trends in the automotive industry appeared. At the same time, there was a turning point in the use of alternative materials in the design of the machine, in addition to steel and cast iron.
It is worth thanking for this increased expectations regarding the durability of machines, new standards for fuel consumption and passive safety. Well, and, traditionally, the development of technologies that allowed all this. Timid attempts to use aluminum in the nodes responsible for passive safety quickly ended with the introduction of only the simplest elements in the form of bars for crushed areas and decorative elements, which in total mass bodies accounted for a few percent.
But the battle for the design of the body itself was hopelessly lost at that time. Plastic manufacturers have clearly won. simple technology making large parts out of plastic changed the design of cars in the eighties. Europeans were surprised at the manufacturability and "advanced" Ford Sierra and VW Passat B3 with their developed plastic body kit. The shapes and materials of radiator grilles, bumpers and other elements eventually began to correspond to plastic parts - something like this is simply unthinkable to be made from steel or aluminum.
Meanwhile, the construction of car bodies remained traditionally steel. The task of increasing the strength of the body and reducing the mass was completed by the transition to a wider use of high-strength steels, their mass in the body was continuously increasing, from a few percent in the late seventies and up to a confident 20-40% by the mid-nineties in advanced designs European brands and 10-15% for American cars.
1 / 4
2 / 4
3 / 4
4 / 4
Corrosion problems were solved by switching to galvanized steel and new painting technologies, which made it possible to increase the warranty period for the body up to 6-10 years. Aluminum remained out of work, its content in the mass of the car even decreased compared to the 60s - the oil crisis played a role, when energy carriers became more expensive, and hence the metal itself. Where possible, it was replaced by plastic, and where plastic was no good, steel again.
Aluminum Strikes Back
Having lost the battle for the exterior, a decade later, aluminum won back under the hood. In the 90s and 2000s, manufacturers massively switched to aluminum gearbox housings and cylinder blocks, and then suspension parts. But that was only the beginning.
The fall in aluminum prices in the 1990s coincided well with the tightening of requirements for the economy and environmental friendliness of cars. In addition to the large components already mentioned, aluminum was registered in many parts and assemblies of the machine, especially those related to passive safety - steering brackets, amplifier beams, motor mounts ... Its natural fragility, a wide range of viscosity changes, and low weight came in handy .
Further - more, aluminum began to appear in the body structure. About the all-aluminum Audi A8 i, but also on more simple machines began to appear external panels from light metal. First of all, these are hinged panels, hood, front fenders and doors on a car. premium brands. Alloy steel subframes, mudguards and even amplifiers. On modern BMW and Audi in the front of the body remained almost one aluminum and plastic. The only place where the positions have become unshakable so far is the load-bearing structures.
1 / 6
2 / 6
3 / 6
4 / 6
5 / 6
6 / 6
About cons and corrosion
Aluminum is always difficult with welding and fasteners. For connection with steel elements, only riveting, bolts and gluing are suitable, for connection with other aluminum parts, welding and screws are also suitable. A few examples of structures using light-alloy bearing elements have proven to be very capricious in operation and superbly inconvenient to restore.
So, aluminum front suspension cups on BMW cars and spars still have problems with electrochemical corrosion at the joints and problems with restoring joints after damage to the body.
As for the corrosion of aluminum, it is even more difficult to deal with it than with the corrosion of steel. At a higher reactivity, its resistance to oxidation is mainly due to the formation protective film oxides on the surface. And this method of self-defense in the conditions of connecting parts from a bunch of different alloys turned out to be useless.
The Steel Challenge That Could Change Everything
While aluminum was conquering new territories, the technologies for the production of rolled steel did not stand still. The cost of high-strength steels decreased, mass hot-forged steels appeared, corrosion protection albeit with slippage, it also improved.
But aluminum is still coming, and the reasons for this are clear to everyone who is familiar with the process of stamping and welding steel parts. Yes, stronger steels make it possible to lighten the car body and make it stronger and tougher. back side medals - an increase in the cost of the steel itself, an increase in the price of stamping, an increase in the cost of welding and the difficulty in repairing damaged parts. Doesn't it remind you of anything? Precisely, these are the very problems that are inherent in aluminum structures from birth. Only high-strength steel and traditional "iron" difficulties with corrosion do not disappear anywhere.
But the same cannot be said about high-strength steel. A package of expensive alloying additives is inevitably lost during processing. Moreover, it contaminates secondary raw materials and requires additional costs for cleaning it. Price for simple stamps steel and high-strength differs significantly, and when iron is reused, all this difference will be lost.
What's next?
Apparently, we are waiting for the aluminum future. As you already understood, the initial cost of raw materials does not play such a role now as manufacturability and environmental friendliness. The growing “green” lobby can influence the popularity of aluminum cars in many other ways, from successful PR to reduced recycling fees. As a result, the image premium brands requires greater use of aluminum and the popularization of technology among the masses, with maximum benefit for yourself, of course.
Steel structures remain the lot of cheap manufacturers, but as aluminum technologies become cheaper, they will certainly not resist the temptation either, especially since the theoretical advantage of aluminum can and even should be realized. While automakers are not trying to force this transition, the body structures of most cars contain no more than 10-20% aluminum.
That is, the "aluminum future" will not come either tomorrow or the day after tomorrow.
In the traditional steel bodybuilding, a bodybuilding dead end is visible ahead, which can only be avoided by breaking the trends for all-round hardening and lightening of structures.
While progress slows down the manufacturability of welding processes and the availability of well-established production processes, which can still be inexpensively adapted to new steel grades. Increase welding current, introduce precise control of parameters, increase compressive forces, introduce inert welding ... As long as these methods help, steel will remain the main structural element. Rebuilding production is too expensive, global changes very heavy for the hulking locomotive of industry.
What about the cost of owning a car? Yes, it is growing and will continue to grow. As we have repeatedly said, modern auto industry developed countries are sharpened for a quick renewal of the fleet and a wealthy buyer with access to cheap loans at 2-3% per annum. About countries with real inflation of 10-15% and salaries of the "middle class" in the region of $ 1,000, corporate managers are far from thinking in the first place. Will have to adjust.
January 13, 1942 appeared the first in the world plastic car. Henry Ford received an official patent for his invention, which, according to the author's idea, was to become lighter and cheaper than a car with a metal body. Due to many objective reasons, such cars have not yet gained popularity. However, this does not prevent manufacturers from time to time to present concepts, and even trial batches of products from this unusual material. And in our today's review we will talk about the ten most interesting and iconic cars from plastic.
During the Second World War, most of the metal produced in the world went to the military. This fact was one of the main reasons for the emergence of Soybean Car - the world's first plastic car. Of course, most of the parts of this car were made of metal, but the design also included fourteen bioplastic elements, which reduced the weight of the car by almost a quarter.
And the first plastic car launched in mass production, became Chevrolet Corvette 1953 release. The frame of this car was made of metal, and the body was made of fiberglass, which was gaining popularity in those years. In total, 300 copies of this car left the assembly line, which served as the progenitor of one of the most popular sports cars in the world.
Experiments with fiberglass bodies took place in those days in the Soviet Union. For example, in 1961, students of the Kharkov Road Institute created an experimental car HADI-2, which became the first domestic plastic car. The weight of the car was only 500 kilograms.
Trabant is not just a car, it is a symbol of the whole country that produced it, the German Democratic Republic. Due to the simplicity of design, small size and constant breakdowns, the car has become the object of universal ridicule. Especially the Germans, who always knew a lot about good cars, amused Trabant's plastic body (wings, bumper and part of the body panels). In total, more than three million cars were produced under this brand.
K67 car, created jointly concern BMW and the chemical giant Bayer, was first shown to the public in Düsseldorf in 1967. But this happened not at a car show, but at an exhibition of the chemical industry. After all, Bayer wanted to show off its achievements in plastics technology in this way. As a demonstration, this car with plastic body crashed into the wall several times without any injury.
plastic car the Urbee Hybrid mobile was also created to demonstrate the development modern technologies. This car was the first car, most of the parts of which (including the body) were printed on a 3D printer.
The BMW i3, which will go into mass production in 2014, will not only be the world's first serial electric car premium class, but also a car in which a significant part of the body parts will be made of carbon fiber reinforced plastic. The creators of the machine expect that in the future this technology will gain immense popularity around the world. After all, such a body is lighter than a completely metal body, and even immune to minor mechanical damage.
As mentioned above, the first mass-produced plastic car was the Chevrolet Corvette sporcar. Company Alfa Romeo continues these glorious traditions. She released sport car Alfa Romeo 4C with full carbon fiber body. This structural element weighs only 63 kilograms, and the car as a whole weighs 895 kg.
also does not graze the rear in the creation of plastic cars. Already on the way to the beginning mass production « people's car” with the funny name Yo-mobile. Its body will be made of plastic and polypropylene. Some panels will be interchangeable. So owners will be able to change them after major accidents or simply change the color of their car if they wish.
Some wits, criticizing plastic cars, call them toys and joke that they are vehicles generally can be assembled from LEGO. As if mocking them, two young engineers, an Australian and a Romanian, jointly created full size car from more than half a million elements of the designer. Interestingly, instead of the engine internal combustion this LEGO car has .
Original taken from mastino_odessa V
Of course, they are not completely plastic. As a rule, we are talking about a plastic body, sometimes even about plastic parts body. However, plastic plays a significant role in the construction of all these cars.
Soybean Car. The world's first plastic
During the Second World War, most of the metal produced in the world went to the military. This fact was one of the main reasons for the appearance of Soybean Car - the world's first plastic car. Of course, most of the parts of this car were made of metal, but the design also included fourteen plastic elements, which reduced the weight of the car by almost a quarter.
Chevrolet Corvette (C1). The first production car made of plastic
And the first plastic car put into mass production was the 1953 Chevrolet Corvette. The frame of this car was made of metal, and the body was made of fiberglass, which was gaining popularity in those years. In total, 300 copies of this car left the assembly line, which served as the progenitor of one of the most popular sports cars in the world.
Experiments with fiberglass bodies took place in those days in the Soviet Union. For example, in 1961, students of the Kharkov Road Institute created an experimental car HADI-2, which became the first domestic plastic car. The weight of the car was only 500 kilograms.
Trabant. The most massive plastic car
Trabant is not just a car, it is a symbol of the whole country that produced it, the German Democratic Republic. Due to the specific design, small size and constant breakdowns, the car has become the object of universal ridicule. Nevertheless, more than three million cars were produced under this brand.
Bayer K67. Pride of the German chemical industry
The K67, created jointly by BMW and the chemical giant Bayer, was first shown to the public in Düsseldorf in 1967. But this happened not at a car show, but at an exhibition of the chemical industry. After all, Bayer wanted to show off its achievements in plastics technology in this way. As a demonstration, this plastic-bodied car crashed into a wall several times without any injury.
Urbee Hybrid. Printed plastic car
The plastic car Urbee Hybrid was also created to demonstrate the development of modern technology. This car was the first car, most of the parts of which (including the body) were printed on a 3D printer.
BMW i3. Luxury plastic electric car
The BMW i3, which will go into mass production in 2014, will not only be the world's first mass-produced premium electric car, but also a car that will feature carbon-fiber-reinforced plastics in a significant part of its bodywork. The creators of the machine expect that in the future this technology will gain immense popularity around the world. After all, such a body is lighter than a completely metal body, and even immune to minor mechanical damage.
Alfa Romeo 4C. plastic sports car
Alfa Romeo has released a sports car Alfa Romeo 4C with a full carbon fiber body. This structural element weighs only 63 kilograms, and the machine as a whole weighs 895 kg.
Yo-mobile. Russian plastic car
The domestic auto industry is also trying to keep up with the creation of plastic cars (at least, projects of such cars). The start of mass production of the "people's car" with the funny name Yo-mobile is already on the way. Its body will be made of plastic and polypropylene. Some panels will be interchangeable. So owners will be able to change them after major accidents or simply change the color of their car if they wish.
This car is known to automotive historians as the Soybean car (“soy car”), it did not have its own name. The idea of a plastic car came to Henry Ford in the late 1930s, and he entrusted the development to his designer, Eugene Gregory. Dissatisfied with the progress of development, Ford handed over the task to a laboratory in Greenfield Village, developing plastics from soybeans and other crops under the direction of engineer Lowell Overly.
By 1941, the concept was developed plastic suitable for the manufacture of body panels, the design of the car was based on the developments of Gregory, and August 13, 1941 "soy Ford" was presented to the public. Big money was invested in the project. Ford had 12,000 acres of soybean fields to experiment with and claimed he could "grow cars in a garden" after the war. Historians still do not understand why the extremely conservative and already very elderly at that time Ford undertook such a project at all. Someone even wrote that it was “senile insanity” (Ford turned 78 in 1941). 
The basis of the machine was tubular frame, on which 14 body panels were attached, made from a composite based on soy, but including hemp, wheat, flax and ramie (Chinese nettle). As a result, the car weighed 860 kg - 25% less than the average car of this class at the time. Engineers were strictly forbidden to disclose the composition of the composite. Lowell Overly let slip several times in interviews that phenol-formaldehyde resin is included in the composition, but nothing more. 
There are legends that a second similar car was made for Ford himself - but there is no real evidence for this. More of these cars were not built, and all of Ford's energy went to military supplies. Sometime during the war, the Soybean car was destroyed on the instructions of Eugene Gregory (apparently he followed Ford's orders in turn) so that the secret of the composite remained within the company. And full-fledged plastic cars appeared only after the war. 
Perhaps the most widespread Renault Espace, which in the first generation acquired plastic body panels that were bolted to an aluminum frame. That is, it is essentially eternal car. It is not surprising that, looking at the cars of the first years of production, you somehow do not notice holes in the body. Renault Espace of the first generation can be bought today for 2,000 rubles. So much in our catalog is asked for a car manufactured in 1990 with a mileage of 333,000 km. It has a two-liter petrol engine and a manual transmission. Yes, the years have not spared this car, but not a speck of rust! Few cars of the first generation survived, but the second generation Espace with the same plastic body is sold more.
The minimum price for a second-generation car is 3,000 rubles. So much asking for a copy of 1993 release. True, it may confuse the fact that under the hood of the car is a 2.8-liter gasoline engine. He is, of course, powerful, but very gluttonous. The price ceiling for second-generation cars is 6,000 rubles. For that kind of money, you will get a 1995 car with a mileage of 270,000 km with a two-liter gasoline engine And gas equipment.
By the way, you can look at the machines of the third generation, which continued glorious tradition the first two do not rust in any conditions.
Renault Espace 1997 release with a mileage of 279,000 km is offered for 5,534 rubles. Under the hood is an eight-valve two-liter gasoline engine seasoned with gas equipment. There is a mass nice extras like Webasto and excellent condition mechanical part.
The most expensive option is a car made in 2002 with a mileage of 270,000 km. They ask for it as much as 14,288 rubles. Somehow expensive, even if you believe in the words about the native mileage and flattered by a 1.9-liter diesel engine.
espace fourth generation had a load-bearing steel body, but it can be safely attributed to stainless steel of the second order - the tailgate and front fenders are plastic, and the side doors and hood are aluminum, so you won’t wait for rust on them. Strength elements bodies are steel, but they will rust only in the event of an emergency past.
The minimum price for a fourth-generation car is 8653 rubles. So much is asked for a 2003 Renault Espace with a mileage of 196,000 km. Under the hood, he has a 2.2-liter diesel engine 150 hp The package is traditionally rich - leather interior, climate control, cruise control, xenon headlights. The maximum price for a French minivan is obscene. The most expensive lot in our ad catalog is sold for 33,003 rubles. This is a 2011 car with 118,458 km mileage. Under the hood is a two-liter diesel engine with a capacity of 130 hp. And the salon - full stuffing up to the monitors in the headrests of the front seats.
Second most popular stainless car in the catalog is Audi A8, whose body, from the first generation to the latest, is made entirely of aluminum. This implies some features in the repair technology and its cost, but when buying a whole copy, it completely eliminates thoughts about corrosion. True, the owner of a used A8 and other thoughts about maintenance and repair will be in abundance.
You can become the owner of an aluminum miracle for 6,000 rubles. That's how much they ask for a 1996 car with a 3.7-liter gasoline engine And all-wheel drive. The price ceiling for a first-generation car (D2 body) ends at 19,722 rubles. They want so much for a car made in 2001 with a mileage of 263,000 km. Under the hood, this instance has a 2.5-liter diesel engine, and the drive is front-wheel drive.
The minimum price for a second generation car (D3) in our catalog of private ads is 12,074 rubles. So much is asked for a car produced in 2003 with a mileage of 220,000 km, with a 4.2-liter gasoline engine and all-wheel drive. per car recent years issue will need to pay three times more. Audi A8 2008 release is sold for 45,279 rubles. A car with a mileage of 166,000 km, with a 4.2-liter gasoline engine and all-wheel drive. A third-generation car manufactured in 2010 can already be bought for only 44,273 rubles. This will be an instance with a mileage of only 130,000 km. Under the hood is the most common 4.2-liter gasoline unit.
Another aluminum car in the model a number of Audi- subcompact van A2. The idea to create a compact stainless steel one-volume premium segment failed. The car lasted on the assembly line for only 6 years, after which it was discontinued. But the sale is full of used A2.
Audi A2 2001 release can be bought for a minimum of 10,000 rubles. Under the hood is a 1.2-liter diesel engine. Average consumption promised at the level of 3.5-4.5 liters per "hundred". The car has climate control, cruise, leather trim and automatic transmission. The maximum that they ask for the Audi A2 is 15,093 rubles. This is how much a car made in 2002 with a mileage of 204,000 km, 1.4-liter diesel engine And mechanical box gears.
Another example of plastic art arrived on the Belarusian market from the USA. There he bore the name Pontiac Trans Sport (or Chevrolet Lumina APV). There are few of these cars in the catalog of free ads, but still they are found. We found a 1994 Pontiac Trans Sport with 220,000 km in European specification with a 2.3-liter petrol engine. The car costs 9056 rubles.
Anything that can rot in the Land Rover Defender- This is a ladder-type steel frame, because all the body parts are made of aluminum. Although at the junction of the "winged" metal with the usual electrochemical corrosion occurs - therefore, holes can be seen in this car.
Finding a British legend for sale is another problem. There were only two copies in our catalog of ads. The most affordable of them costs 24,149 rubles. This is a 2002 Defender with 145,000 km and a 2.5 liter diesel engine.
Smart is arranged in much the same way as the rest of the plastic world of cars - it is based on a rigid steel frame, hung with plastic panels. Such a structure will rust only if the steel load-bearing frame is damaged in an accident. The most affordable Smart can be bought for 4,023 rubles. This is the price of a car manufactured in 2000 with a mileage of 170,000 km and a 0.6-liter gasoline engine.
A car manufactured in 2010 with a mileage of 76,500 km and a powerful 1-liter engine is sold for 15,000 rubles.
Incidentally, the first stock car with a plastic body is considered the Chevrolet Corvette C1. It was based on a spatial tubular frame with fiberglass panels. Corvette latest generation assembled on a spatial aluminum frame, with a roof and hood made of carbon fiber and other parts made of composite materials. But in our ads there was only one Corvette - the fifth generation, with fiberglass body panels. A 2000 Chevrolet Corvette with a mileage of 80,000 km is sold for 38,236 rubles. Under the hood - 345 hp, taken from the mighty 5.7 liters of V8. In winter, the car did not drive, was stored in a garage under a cover. However, winter races would not hurt him.
A stainless steel car is, with some reservations, quite a real thing. And you can even buy it. In most cases, even buying a used car with plastic body panels or with an aluminum body, you completely save yourself from problems with through holes, "beetles" and other manifestations of corrosion. But plastic and aluminum have their own difficulties in repairing and painting. This must be remembered when choosing a stainless car.
