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The Use of Al 5754 and 3003 in Automobile

The choice of automotive aluminum sheets is essentially about precisely matching performance with the application. Although 5754 and 3003 belong to the same rust-resistant aluminum family, their alloy compositions offer distinct core advantages.

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5754 Aluminum Alloy

As a typical aluminum-magnesium alloy, 5754 utilizes 2.6%-3.6% magnesium as a core strengthening agent, combined with 0.5%-0.8% manganese to adjust Al 5754 properties, resulting in a unique combination of "medium strength + exceptional ductility":

Mechanical Properties: Flexible performance range across different tempers. Elongation in the O state (annealed) can reach 12%-20%, making it suitable for deep drawing. The H34 temper’s tensile strength is increased to 260-310 MPa, meeting the strength requirements of structural parts.

Core Advantages: A dense oxide film forms on the surface, offering excellent corrosion resistance to freshwater, seawater, and weak acids, making it particularly suitable for humid or coastal environments. It can be easily welded using methods such as argon arc welding and resistance welding, achieving joint strength close to that of the parent material.

Processing Characteristics: Excellent stamping performance is maintained across thicknesses from 0.2 to 8mm. It resists cracking during complex curved mold forming, has a high surface finish, and offers strong adhesion during subsequent spraying and anodizing treatments.

3003 aluminum alloy

3003 aluminum alloy, with manganese as the primary alloying element, is an excellent choice for thermal management and protection components due to its unique composition. The following are Al 3003 properties:

Mechanical Properties: Strength is slightly lower than 5754, but plasticity and formability are well-balanced. The O temper can be easily punched and stretched, while the H14 grade offers a balance of strength and processing efficiency.

Core Advantages: It offers benchmark rust resistance and long-term stable operation in humid environments without the need for additional coatings. Its excellent thermal conductivity significantly improves brazing performance when combined with cladding layers such as 4045 and 4343, making it an ideal material for heat dissipation components.

Processing Characteristics: Available in thicknesses of 0.8-3.0mm, it is specifically designed for components such as cooling plates. It offers excellent stamping consistency and enables mass production of complex flow path structures. Its material recovery rate exceeds 95%, meeting environmental standards.

Applications

1. 5754 aluminum sheet

Body panels: It is a preferred material for key components such as inner car door and hood outer panels. Its deep-drawing performance meets the requirements for complex curved surface forming, while its moderate strength ensures structural integrity during collisions. Its lightweight properties enable a 15%-20% weight reduction per vehicle.

Fluid storage components: Tank truck bodies and automobile fuel tanks rely on its corrosion resistance and weldability. The tightness of welded joints effectively prevents leakage of fuel or transported media, extending component life to more than twice that of traditional steel.

Chassis accessories: Components such as seals and mold bases leverage its stable dimensional accuracy and fatigue resistance to maintain stable performance even under chassis vibration, reducing subsequent maintenance costs.

2. 3003 aluminum sheet

Power battery components: New energy vehicle power battery housings, roof panels, and partitions are primarily made of 3003 aluminum sheet. The high plasticity of the O temper allows for stamping into square or round housings. Its rust-resistant properties protect the battery from humid environments, enhancing safety.

Core thermal management components: Brazed water cooling plates are a star application of 3003. Formed by brazing 3003+4045 composite sheets, these plates quickly dissipate heat from the battery, keeping the battery operating temperature within the optimal range of 25-40°C, and improving heat dissipation efficiency by 30% compared to traditional materials.

Protective and interior components: Automotive heat shields utilize their heat resistance and formability to block engine heat transfer to the cockpit. Bus skins leverage their wide-width processing capabilities and rust resistance to achieve a balance between lightweight and durable bodywork.

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