Looking forward to a new Audi A8: Space Frame with a singular brew of materials

Posted on 05. Apr, 2017 by in Audi Canada

The lightweight pattern experts during Audi prolonged ago deserted a emplacement on controlling a singular element in lightweight design. With a brew of aluminum, steel, magnesium and CO fiber-reinforced polymer (CFRP) they are substantiating a new theatre in multi-material construction in a Audi Space Frame (ASF) for a subsequent era of a Audi A8 – in gripping with a element “the right element in a right place and in a right amount.”

Audi consistently relates new element technologies and designs that directly advantage a patron – and not usually in terms of weight. The arriving flagship’s torsional acerbity – a vicious parameter for accurate doing and appreciative acoustics – surpasses a glorious values of a prototype by a cause of about one fourth.

Innovative prolongation routine – a CO back row in a new Audi A8
In terms of a altogether dimensions, an ultra-high-strength, torsionally firm back row done of CFRP is a largest member in a passenger dungeon of a new Audi A8, and it contributes 33 percent to a torsional acerbity of a sum vehicle. To optimally catch longitudinal and cross loads as good as shearing force, between 6 and 19 fiber layers are placed one on tip of a other, ensuring a load-optimized layout. These particular fiber layers include of tapes 

50 millimeters (2.0 in) wide and can be placed away in a finished layered package, with any preferred fiber angle and minimal pleat of a fibers. The innovative direct-fiber layering routine specifically grown for this purpose creates it probable to wholly allot with a routinely indispensable surrogate step of prolongation whole sheets. Using another newly grown process, a layered package is wetted with epoxide creosote and sets within minutes. 

A high-strength multiple of hot-formed steel components make adult a passenger cell, that comprises a revoke territory of a front bulkhead, a side sills, a B-pillars and a front territory of a roof line. Some of these piece steel blanks are constructed in varying thicknesses controlling tailoring technologies – definition they are customized – and others also bear prejudiced feverishness treatment. That reduces weight and increases a strength, generally in areas of a automobile that are quite vicious for safety.

The aluminum components make adult 58 percent of a new Audi A8 body, a largest share in a brew of materials. Cast nodes, extruded profiles and sheets are a elements evil of a ASF design. And here too a foe of materials has been pushing progress. New heat-treated, ultra-high-strength expel alloys achieve a tensile strength of over 230 MPa (megapascals). The analogous produce strength in a tensile exam is over 180 MPa, and for a form alloys it is aloft than 280, i.e. 320 MPa – significantly aloft values than seen previously.

Rounding out a intelligent brew of materials is a magnesium strut brace. A comparison with a prototype indication shows that it contributes a 28-percent weight savings. Aluminum bolts secure a tie to a strut building domes, creation them a guarantor of a body’s high torsional rigidity. In a eventuality of a frontal collision, a army generated are distributed to 3 impact buffers in a front end.

Benefits for business and a sourroundings – a new physique emporium for a Audi A8.
In further to a finish redevelopment of a Audi Space Frame for a subsequent era A8, a prolongation halls during a Neckarsulm plcae were specifically built for a arriving flagship. A sum of 14,400 metric tons of steel were indispensable only for construction of a new, 41-meter-high physique shop, twice as most steel as was used for a Eiffel Tower in Paris.

The rarely formidable nonetheless energy-efficient prolongation operation uses 14 opposite fasten processes, including drum hemming during a front and back doorway cutouts. This mechanical, “cold” record is used to join a aluminum side wall support to a hot-formed, ultra-strong steel sheets during a B-pillar, roof line and sills. The engineers so satisfied improvements of adult to
36 millimeters (1.4 in) during a doorway cutouts compared to a prototype model. That in spin creates removing in and out of a automobile even some-more gentle and widens a driver’s margin of prophesy around a A-pillar, an area that is pivotal to protected driving.

As for a “warm” fasten processes, Audi stands alone among a reward automakers by trait of a growth of remote laser welding for use with aluminum. Exact positioning of a laser lamp in propinquity to a welding corner extremely reduces a risk of prohibited enormous during a prolongation process. The new routine creates it probable to precisely control a invasion abyss of a laser by means of a feverishness input. In this way, routine control can immediately establish a opening breadth between tools being joined, and this can effectively be sealed controlling regulating controls. The laser beam’s high feed rate and low appetite use revoke a CO2 emissions of this prolongation step by about one fourth.

This new routine also formula in a 95 percent assets on repeated costs in array prolongation since it eliminates a need for dear routine controls compulsory with required laser welding. The remote laser welding record ideally symbolizes a whole prolongation of a new Audi A8.

In 1994 it was a initial era of this oppulance sedan, with a aluminum unitary body, that done a Audi Space Frame an determined participation in a automotive world. Since afterwards a association has built some-more than one million prolongation cars in suitability with this pattern principle, and it has been ceaselessly building on a expertise in a use of materials and fasten techniques.

More information about physique growth during Audi can be found in a Audi Media Center at www.audi-mediacenter.com/en/presskits/techday-body-structure-7469.

Fuel expenditure of a models named above:

Audi A8 (coming generation):
This automobile is not nonetheless on sale. It does not nonetheless have form capitulation and is therefore not theme to Directive 1999/94/EC.

Audi A8 (current model):
Combined fuel expenditure in l/100 km: 11.2 – 5.7** (21.0 – 41.3 US mpg);
Combined CO2 emissions in g/km: 259 – 146** (416.8 – 235.0 g/mi)

**Fuel consumption, CO2 glimmer total and potency classes given in ranges count on a tires/wheels used. 

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