Aluminium Grades & Sustainability
Aluminium Grades & Sustainability
HFQ® Technology (for high speed aluminium hot forming) has been developed to form complex geometries to high tolerance for heat treatable and ultra-high strength aluminium sheet alloys, including AA6xxx, AA7xxx and AA2xxx series that are common in the automotive and aerospace sectors.
Moreover, HFQ® can be applied to recycled AA6xxx grades, with a high percentage of secondary aluminium content, which can lead to a reduction in embedded carbon in a structure.
HFQ® Technology, unlike cold forming, can also be used for alloy sheet supplied in the F-temper condition, which offers the potential for cost reduction and a wider range of suppliers than for alloys supplied in the T4 state. Because the HFQ® process resets the aluminium, shelf-life limitations, which can affect sheet purchased in the T4P condition, are not an issue.
Aluminium grades for HFQ®: providing choice for performance and value
HFQ Technology Associates has accumulated significant expertise and experience to support design engineers and procurement leads to offer choice of accredited aluminium alloy grades and sources, all characterised to a common technical standard. We have over 20 grades ready for hot forming simulation and processing, and our Materials Evaluation Centre can, in a short period, characterise any alloy from any global supplier of your choosing to ensure it is ready for new component design and manufacture. Also, we can provide hot forming simulations, design support and process data for F-temper (as fabricated and lower cost) versions of these grades.
Choice of supply allows engineers to find the optimum grade to achieve maximum light-weighting benefits and strength (up to 500MPa yield strength for some grades) whilst ensuring the lowest possible cost. Our experts can conduct hot forming simulations to ensure that a part is able to be made from a choice of alloys, providing interchangeability of supplier and thereby some purchasing leverage for aluminium sourcing. Given that, in high volumes up to 70% the cost of a hot pressed HFQ® part can be attributed to the aluminium blank, choice of supply can give rise to significant cost savings.
In addition to offering a wide range of existing alloys and the potential to characterise any alloy of a client’s choosing, ITL has expertise in the hot forming of tailor-welded blanks (TWBs), that can enable structures of multiple thicknesses (for B-pillar reinforcements, for example) and improved raw material utilisation versus conventional blanks. A unique characteristic of HFQ® for TWBs is the avoidance of heat affected zone (HAZ) issues with the aluminium weld; as the HFQ® process ‘resets’ the sheet strength during the solutionising, quenching and aging stages.
Environmental benefits of HFQ®: pioneering sustainable lightweight structures
ITL has demonstrated the potential to use 100% recycled aluminium, including high level of post-consumer scrap, for high strength HFQ® hot formed structures. Working in collaboration with aluminium supplier Gränges, ITL has successfully produced two 100% recycled structures in 6082 alloy: an A-pillar for a car body-in-white and a low-cost aircraft seat back. The use of fully recycled aluminium, can reduce embedded carbon by up to 95%, depending on the production origin; and also reduce the other environmental effects of using primary aluminium.
The carbon content of aluminium sheet can vary considerably depending on the carbon intensity of the electricity grid at the place of production (China being higher than Europe, for example) and the level of recovered scrap used. ITL experts can support OEMs to ensure that aluminium grades with the lowest embedded carbon are ready for design through materials characterisation and provision of HFQ® formed test coupons.
A wide range of applicable alloys
Different grades of aluminium apply to applications according to a range of factors including strength, ductility, corrosion, availability and cost. Impression Technologies’ applications experts can provide guidance on alloy selection or work with any specified grade chosen by the OEM.
HFQ-TA continues to expand the range of alloy grades and suppliers that are ready for production using the HFQ® process, particularly F-temper and continuous cast grades. If the grade is not listed below, HFQ-TA can, in collaboration with the alloy supplier, accredit new grades or sources in time for the design of a new component. HFQ-TA is also in discussions with some aluminium companies to develop new ultra-high strength grades that exploit the full potential of HFQ®, thereby increasing strength and offering the path to lower material input costs.
6082
Suitable for:
Automotive/EV, aerospace interiors, mass transit, bicycles
Number of alloy suppliers characterised for HFQ® simulation/manufacture: 3
Indicative HFQ® Part T6 Yield Strength (MPa): 280-325
6082-Recycled
Suitable for:
Automotive/EV , aerospace interiors, mass transit, bicycles
Number of alloy suppliers characterised for HFQ® simulation/manufacture: 1
Indicative HFQ® Part T6 Yield Strength (MPa): 285-330
6111
Suitable for:
Automotive/EV
Number of alloy suppliers characterised for HFQ® simulation/manufacture: 2
Indicative HFQ® Part T6 Yield Strength (MPa): 305-348
6014
Suitable for:
Automotive/EV
Number of alloy suppliers characterised for HFQ® simulation/manufacture: 1
Indicative HFQ® Part T6 Yield Strength (MPa): 250-299
6016
Suitable for:
Automotive/EV
Number of alloy suppliers characterised for HFQ® simulation/manufacture: 1
Indicative HFQ® Part T6 Yield Strength (MPa): 250-299
UHS6111
Suitable for:
Automotive/EV
Number of alloy suppliers characterised for HFQ® simulation/manufacture: 2
Indicative HFQ® Part T6 Yield Strength (MPa): 350-375
7075
Suitable for:
Automotive/EV, seats, aerospace interiors, consumer electronics
Number of alloy suppliers characterised for HFQ® simulation/manufacture: 3
Indicative HFQ® Part T6 Yield Strength (MPa): 470-520
2024
Suitable for:
Aerospace
Number of alloy suppliers characterised for HFQ® simulation/manufacture: 1
Indicative HFQ® Part T6 Yield Strength (MPa): 315-399
2219
Suitable for:
Aerospace
Number of alloy suppliers characterised for HFQ® simulation/manufacture: 2
Indicative HFQ® Part T6 Yield Strength (MPa): 250-320
Sustainable Lightweighting
Users of HFQ® Technology will unlock the potential of HFQ® to create more lightweight components with fewer individual parts, resulting in reduced raw material consumption, streamlined manufacturing processes, and lower carbon emissions during production and assembly.
With HFQ®, road vehicles, aircraft, rail systems, and consumer products become inherently lighter, leading to decreased emissions during use and substantial lifetime carbon savings. By embracing HFQ® Technology, manufacturers are on the way to driving sustainability, efficiency, and innovation across industries while making a positive impact on the planet.
Ask us about sustainable lightweighting
We welcome enquiries from OEMs, tiers, design consultancies and alloy producers looking for a new approach to reduce cost, complexity and carbon footprint. Our technical experts will be pleased to arrange a consultation and provide initial guidance.