Low cost aluminium closures

Young, Lisa (2005) Low cost aluminium closures. University of Southampton, Doctoral Thesis.

Record type: Thesis (Doctoral)

Abstract

Low cost aluminium closures are a new design of closure (hood, door or tailgate) for automotive vehicles. A closure is made from an outer and inner panel and other components such as: hinges, latches, strikers and reinforcements. A low cost aluminium closure has a pre-coated aluminium outer panel joined to a zinc coated steel inner panel with additional components made of zinc coated steel.

Low cost aluminium closures have been shown herein to be at least as corrosion resistant as the existing all zinc coated closure and the structural durability of low cost aluminium closures meets the specified performance level. The existing hem flange adhesive is suitable for low cost aluminium closures and an optimised two part epoxy has been evaluated and would be recommended for use on large closures where increased handling strength is required. Manufacturing feasibility has been investigated and low cost aluminium closures can be manufactured in Ford of Europe production plants with minimal changes to existing production lines. The part cost of low cost aluminium closures has been established and taking into account the cost reduction associated with weight saving low cost aluminium closures can be manufactured for significantly less than the existing closure.

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