Structural durability proof of automotive aluminium safety components - present state of the art

Trends in increasing usage of aluminium-alloys for vehicle safety components require one to summarize the state of the art related to the approval of their service strength including the aspects of reliability and safety. For this, it is necessary to describe the design criteria for the vehicle safety components manufactured from aluminium alloys, which include the evaluation of the structural yield point, the fracture behaviour and the fatigue life - three main parameters for the components´ service strength. In this paper the procedures for the experimental and the numerical service strength evaluation of cast, forged and welded aluminium-alloy safety components are presented. Also the results of investigations of environmental influences (corrosion, elevated temperature) as well as the methods for accelerated test approval are presented, validated and a practical approach are presented, validated and a practical approach recommended. Finally, further investigations are proposed as being of importance in determining additional data necessary for a reliable design.