At present, 6016 aluminum alloy automotive sheet has attracted much attention for its excellent performance. This paper discusses the whole process production technology of 6016 aluminum alloy automobile sheet, including chemical composition, melting and casting, rolling, heat treatment, chemical treatment and electrostatic oiling, and emphatically expounds the basic principle, technical status and research progress of each production process. It finally prospects the development directions of 6016 aluminum alloy automobile sheet production technology in aspects of chemical composition design, new melting and casting technology, short process rolling technology, heat treatment technology, chemical treatment technology and key equipment localization.

For the instrument panel beams made mainly of steel, aluminum-magnesium alloy, and composite material, this paper compares the instrument board beams of different processes in terms of lightweight, accuracy, and cost, studies and analyzes the use scenarios and application trends of instrument panel board, and compares the technical defects and process restrictions of different types of instrument panel beams. The study believes that with the general use of composite material beams, the cost advantage of steel beams and the lightweight advantages of aluminum-magnesium alloy beams will no longer be significant, while composite material beams will become the mainstream trend of process manufacturing.

To explore the application value of topological optimization design method based on additive manufacturing in the field of commercial vehicle lightweighting, this paper proposes 2 types of optimization schemes through the optimization process of topological calculation, geometric reconstruction and print simulation analysis taking the commercial vehicle post processor bracket as the test object, and the Selective Laser Melting (SLM) process is utilized to complete the physical additive manufacturing. Finally, both schemes pass the verification of the 8 000 km enhanced road bench test, the results indicate that the topology optimization design method based on additive manufacturing fulfills the design and performance requirements.

This paper analyzes and summarizes the impact of China’s natural environment, industrial atmospheric environment and road conditions on the occurrence and acceleration of corrosion in automotive metal materials. The results show that temperature, relative humidity, soil acidity and alkalinity, salt spray in coastal areas, road deicing salt, and industrial atmospheric pollutants are key factors that induce and accelerate the corrosion of vehicle bodies and components. Therefore, in automotive development, rational anti-corrosion design should be made based on these key factors, and corresponding corrosion verification methods should be established to improve the compatibility between the anti-corrosion performance of vehicles and their actual corrosion life, thereby reducing quality issues and cost waste telated to anti-corrosion.

In this study, taking the sealing structure of oil pump flanges as the research object, a rough peak contact model and a parallel flat plate leakage model are further established to calculate the leakage rate of the sealing surface based on the contact pressure distribution on the sealing surface obbtained by finite element mechanical analysis. At the same time, the time-temperature equivalent model of rubber performance is established by rubber accelerated aging test so as to predict rubber sealing life. Finally, the rubber sealing life is verified by seal leakage rate bench test, proving that the test result is basically consistent with the prediction result.

Gap interference exists between the left front combination lamp and the fender of a vehicle model. The design requirement is (1.2±1.0) mm. To ensure the exterior fit meets the design requirements, this paper analyzes the issue from a dimensional perspective. PolyWorks software is used to make dimensional measurements on the beam and side panel assembly, and the headlamp is virtually installed to simulate its posture for verification. This paper also concludes the impact of the parallelism deviation of the integrated bracket mounting surface on the BIW frame on the headlamp’s posture. Combining this with the actual welding process on site, the body fixtures are adjusted and the gap interference issue between the headlamp and the fender is solued ultimately.

Based on the characteristics of e-ink, flexible segment-code e-ink diaphragm is used to integrate with the trim strip of a vehicle, in order to explore the feasibility of integrating e-ink and interior parts, and the vehicle specification test is conducted. Environmental tests show that the e-ink diaphragm or module can withstand the high and low temperature range of -40~70 ℃, and the e-ink diaphragm will be damaged if the temperature exceeds 70 ℃. The alternating test in the temperature range of -30~85 ℃ is easy to cause the wrinkle or stratification of the multi-layer structure of the module. Therefore, the structure and material of e-ink cannot fully meet the automobile specification test, and further research is needed to identify the application potential of e-ink in automobile interior parts.

At present, the automotive industry mainly through the process monitoring based on coating specifications, as well as the result monitoring based on the final bonding effect to effectively ensure the quality of the coating. In order to improve coating quality detection efficiency, this paper, by learning from to the ultrasonic welding spot nondestructive testing technology, explores the application of ultrasonic phased array technology in the detection of body glue, and proves its feasibility theoretically, Moreover, this paper also uses ultrasonic phased array nondestructive testing instrument for practical application inspection, and finally realizes the nondestructive testing of body glue.

Using patent analysis methods, this paper analyzes the patent layout of automotive hot stamping dies from the perspectives of patent application trends, regional distribution, and applicants, and taking automotive B-pillar hot stamping dies and automotive longitudinal beam hot stamping dies as examples to interprets important patent technical solutions. From a patent perspective, this paper analyzes the development status of automotive hot stamping die technology from both macro and micro perspectives, and provides reference for subsequent research, development and innovation directions in the field of automotive hot stamping die technology.

In order to evaluate the feasibility of the application of thin Al-Si coated hot formed steel in automobile body, hot stamping test, spot welding test, adhesive matching test and coating test and corrosion resistance test are carried out on single-sided Al-Si coated materials with the weight of 20 g/m² (AS20) and 75 g/m² (AS75). The results show that: AS20 material can use the same heating temperature as the AS75 material, but the heating time is less than the AS75 material; under the optimal heating process, the mechanical properties of the two materials are comparable; the ultimate sharp cold bending angle and maximum force of the AS20 material are higher than those of the AS75 material; the shear strengths of the adhesive joints between the two materials and the structural adhesive currently used in production are comparable, the AS20 material matches well with the structural adhesive currently used in production; the peeling diameter of the fully damaged welding point and the fusion diameter and failure mode of the welding assembly where the two materials are located are equivalent, the spot weldability of the AS20 material is equivalent to that of the AS75 material; the adhesion and corrosion resistance of the electrophoretic paint film of the two materials are comparable. Overall, based on multi-performance comparative evaluation analysis, the main application properties of thin aluminum silicon coated hot formed steel meets the using requirements of OEMs.