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BMW Group Standard/Aluminium sheet materials for body and chassis

The car body accounts for about 30% of a vehicle’s total mass. Approximately 70% of fuel consumption is associated with body mass, so aluminium adoption for automotive bodies is critical to improving the vehicle’s overall fuel economy.

The chassis is the system with the greatest lightweighting potential and the easiest commercial implementation. TRIP steel is currently the mainstream material, and aluminium alloy has become a core alternative for parts such as suspension components.

For aluminium sheets used in automotive bodies and chassis, the primary grades are 5xxx and 6xxx series aluminium alloys. The 5xxx series delivers outstanding formability and corrosion resistance, while the 6xxx series balances strength and excellent surface quality. It is the dominant material for BIW closures and structural components.

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Mechanical properties AL5 alloys

Grade	Condition	Thickness mm	Tensile strength Rm MPa	Yield point Rp0,2 MPa	Elongation at break A80mm %	Uniform elongation Ag %	Vertical anisotropy r10%	Strain hardening exponent n5%	Yield point ratio Rp/Rm
AL5--IIC 1)	O/H111	0,50 bis/to 4,00	≥ 200	85 bis/to 130	≥ 20	≥ 18	≥ 0,55	≥ 0,26	--
		4,00 bis/to 9,00	≥ 200	90 bis/to 130	≥ 19	≥ 16	≥ 0,55	≥ 0,25	--
AL5--STD 2)	O/H111	0,50 bis/to 4,00	≥ 255	110 bis/to 160	≥ 23	≥ 20	≥ 0,60	≥ 0,26	≤ 0,60
AL5--STO 2)	O/H111	0,50 bis/to 4,00	≥ 255	110 bis/to 160	≥ 24	≥ 21	≥ 0,60	≥ 0,30	≤ 0,60
AL5--HYB 2)	O/H111	1,40 bis/to 1,60	≥ 250	105 bis/to 150	≥ 26	≥ 23	≥ 0,60	≥ 0,28	≤ 0,55
1) This alloy is resistant to intercrystalline corrosion. In case of doubt the resistance shall be proven as described in section 7.4. 2) This alloy is susceptible to intercrystalline corrosion (see section 7.4).

Mechanical properties AL6 alloys as delivered

Grade	Condition	Thickness mm	Tensile strength Rm MPa	Yield point Rp0,2 MPa	Elongation at break A80mm %	Uniform elongation Ag %	Vertical anisotropy r10%	Strain hardening exponent n5%	Yield point ratio Rp/Rm
AL6--OUT 1)	T4	0,90 bis/to 1,50	≥ 190	90 bis/to 1302)3)	≥ 24	≥ 20	≥ 0,60	≥ 0,26	≤ 0,55
AL6--HYF	T4	< 3,0	≥ 220	120 bis/to 1702)4)	≥ 22	≥ 18	≥ 0,55	≥ 0,23	≤ 0,60
AL6--HYC	T61	< 3,0	≥ 220	150 bis/to 200	≥ 18	≥ 14	≥ 0,50	≥ 0,18	≤ 0,80
AL6--CHA	T4	2,5 bis/to 5,0	≥ 200	130 bis/to 1702)5)	≥ 20	≥ 16	--	--	≤ 0,70
The determination of suitability for hemming is performed according to AA--0518. Target value: minimum evaluation level 6 according to method A. Test carried out by supplier between 3 and 10 days after solution heat treatment. Rp0,2 max. 115 MPa andRm min. 180 MPa at time of test. Rp0,2 max. 155 MPa andRm min. 210 MPa at time of test. Rp0,2 max. 155 MPa andRm min. 190 MPa at time of test.

Mechanical properties AL6 alloys after in cured condition

Grade	Condition	Tensile strength Rm MPa	Yield point Rp0,2 MPa	Elongation at break A80mm %	Standardized bending angle (tref= 1,5 mm) αnorm 。
AL6--OUT	T641)4)	≥ 260	≥ 195	≥ 14	--
AL6--HYF	T642)4)	≥ 265	≥ 220	≥ 14	≥ 805)
AL6--HYC	T642)4)	≥ 265	≥ 220	≥ 14	≥ 1105)
AL6--CHA	T63)	≥ 280	≥ 260	≥ 10	--
1) Thermal treatment (185 ± 2) 。C for a dwell time of 20 min, 2 % pre-strain. 2) Thermal treatment (180 ± 2) 。C for a dwell time of 20 min, 2 % pre-strain. 3) Thermal treatment (205 ± 2) 。C, 45 min heating time, 60 min dwell time, 50 min cooling time. 4) The heating of the specimen to the required temperature and the cooling after duration shall be conducted fast enough to avoid additional heat treatment effects due to the heating and cooling process. 5) Specimen transverse to rolling direction. Thermal treatment (180 ± 2) 。C for a dwell time of 20 min, 10 % pre-strain. Test according to VDA 238--100. Bending line parallel to rolling direction.

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Chemical composition AL5 alloys

Grade	Layers	Si	Fe	Cu	Mn Mg Cr Massenanteil in %			Zn	Ti	Al
		Percent by weight
AL5--IIC1)		≤ 0,40	≤ 0,40	≤ 0,10	≤ 0,55	2,6 bis/to 3,2	≤ 0,30	≤ 0,20	≤ 0,15	Rest Remain
AL5--STD2)		≤ 0,20	≤ 0,35	≤ 0,15	0,20 bis/to 0,50	4,0 bis/to 5,0	≤ 0,10	≤ 0,25	≤ 0,10	Rest Remain
AL5--STO2)		≤ 0,20	≤ 0,35	≤ 0,15	≤ 0,50	4,0 bis/to 5,0	≤ 0,10	≤ 0,25	≤ 0,10	Rest Remain
AL5--HYB2)	Core3) AlMg5,3	≤ 0,30	≤ 0,35	≤ 0,15	≤ 0,50	5,00 bis/to 5,50	≤ 0,10	≤ 0,25	≤ 0,15	Rest Remain
	Clad layer4) AlMg1	≤ 0,30	≤ 0,50	≤ 0,20	≤ 0,20	0,70 bis/to 1,10	≤ 0,10	≤ 0,25	≤ 0,15	Rest Remain
1) This alloy is resistant to intercrystalline corrosion. In case of doubt the resistance must be proven as described in section 7.4. 2) This alloy is susceptible to intercrystalline corrosion (see section 7.4). 3) Thickness of the core: 80 % to 90 % of the nominal thickness. 4) Thickness of the clad layer per side: 5 % to 10 % of the nominal thickness.

Chemical composition AL6 alloys

Grade

Mg Cr Zn Massenanteil in %

Percent by weight

AL6--OUT

AL6--HYF

AL6--HYC

AL6--CHA

0,50

bis/to

1,50

≤ 0,35

≤ 0,25

≤ 0,20

0,25

bis/to

0,90

≤ 0,15

≤ 0,10

≤ 0,15

≤ 0,10

Rest

Remain

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