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Large-sized and Lightweight Aluminum Hollow Diecast Subframe Using High Pressure Diecasting

Article of Honda R&D Technical Review Vol.29 No.1

Summary

A large-sized, lightweight aluminum, hollow diecast subframe with increased strength was developed. Technology for baking the entire interior of the core, which is the key to realizing a closed section structure, and materials with enhanced castability were applied to the subframe for the first time known to date, and realized a thin wall structure even with high-pressure diecasting. In addition, the use of a seamless closed-section structure increased the package efficiency and achieved weight reduction of approximately 46% while securing the same stiffness as that of a welded steel plate subframe. These developments realized a top-class lightweight subframe.
The developed subframe was mounted in the CLARITY FUEL CELL, and both reduced the vehicle weight and facilitated fuel cell power train installation under the front hood, achieving high package efficiency equivalent to that of a vehicle with an internal combustion engine.

Reference

(1) Kimura, K., Kawasaki, T., Ohmura, T., Atsumi, Y., Shimizu, K.: Development of New Fuel Cell Vehicle CLARITY FUEL CELL, Honda R&D Technical Review, Vol. 28, No. 1, p. 1-8
(2) Miyahara, T., Sayama, M., Yahaba, T., Ohhama, S., Hata, T., Kobayashi, T.: Development of Steel and Aluminum Continuous Welding Technology Using FSW and Application to Subframes, Honda R&D Technical Review, Vol. 25, No. 1, p. 72-78
(3) Koiwai, S., Kitsunai, T., Yageta, K., Kambe, H., Okane, T., Yamagata, H., Yoshida, M.: Development of Large Scale Thin Wall and Hollow Shape Aluminum Alloy Casting for Automobile Body Parts by using Low Pressure Diecasting, Journal of Japan Foundry Engineering Society, Vol. 84, No. 8, p. 477-481, (2012) (in Japanese)
(4) Koya, E., Suzuki, T., Nakagawa, M., Fujimoto, G., Murakami, M., Murata, K.: Development of Hollow, Weld-able Die-Cast Parts for Aluminum Motorcycle Frames, SAE Technical Paper, 2003-32-0055, (2003)
(5) Asami, A., Imanishi, T., Okazaki, Y., Ono, T., Tetsuka, K.: Development of Aluminium Hollow Subframe Using High-Pressure Die Casting, SAE Technical Paper, 2016-01-0406, (2016)

Author (organization or company)

Tomoyuki IMANISHI(Automobile R&D Center)、Akihiko ASAMI(Automobile R&D Center)、Yuichiro SANEYOSHI(Automobile R&D Center)

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