Manufacturing of light aluminum products for ground transportation

Photo courtesy of Rio Tinto Alcan

NRC works with companies at all stages of the aluminium transformation process, from aluminium smelters plants to manufacturers of finished products. We help them improve their manufacturing processes in order to produce safe, lighter, more cost‑effective and more environmentally friendly vehicles. Our research help companies meet their requirements to produce high‑quality components at competitive costs and we reduce the risks associated with developing new products by validating and optimizing their manufacturing processes.

Partnership opportunity

With the launch of the new ALTec consortium, dedicated to reducing vehicles weight by using aluminium components, companies have the opportunity to join the initiative by selecting one, two or all three consortium thrusts and adopting the resulting technology to their needs. Member companies represent all parts of the component supply chain: producers of primary metal, parts manufacturers of semi‑finished products, assemblers and equipment suppliers (welding, adhesives, casting and corrosion protection). The consortium features three major thrusts:

Preparing for an aluminium die-casting experiment

1. "Light assembly" focuses on developing optimized assembly processes using welding and structural adhesives to address the challenges related to manufacturing aluminium and other light materials components.
2. "Advanced forming" develops technologies for forming aluminium components using next-generation forming and casting processes. The goal is to help companies produce high quality high strength and complex parts that can be manufactured at a frequency and at costs that are competitive.
3. "Durability" develops methods for testing vehicle parts in corrosion and erosion conditions representative of northern road conditions found in countries such as Canada and the northern United States. The goal is to develop practical solutions adapted to aluminium assemblies to withstand these harsh conditions.

Benefits for members

NRC's 5 axis friction stir welding machine

Automobile manufacturers need to manufacture significantly more fuel-efficient vehicles to comply with CAFE standards by the year 2020. Increasing the use of aluminium in vehicles is acknowledged as one of the most effective way to meet these strict standards. NRC will help its clients acquire the necessary technology to become leaders in aluminium vehicle lightweighting. The ALTec consortium members will have access to the expertise necessary to adapt their products to aluminium and multi‑material assemblies.

Consortium members enjoy the following benefits:

• Significant leverage for their R&D investment by sharing the R&D cost with other consortium members
• Access to cutting‑edge expertise, large‑scale research equipment and expertise
• The opportunity to direct consortium priorities to fit with their needs
• The opportunity to network with members from different parts of the supply chain.

Other services and facilities

NRC offers companies a wide range of services and facilities related to aluminium transformation processes. Our clients include companies not only in the automotive and ground transportation industries, but also in aeronautics, shipbuilding, construction and energy.