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10/03/2010
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Dipl-Ing Heinrich Timm, head of the Audi Lightweight Design Centre
 Audi led aluminium-intensive car development, with the A8 in 1994, so Automotive Design asked its head of lightweight design, Dipl-Ing Heinrich Timm, about the carmaker's approach to aluminium, compared, for example, to that of Jaguar.
"Jaguar has been in partnership with Alcan for decades. Their body concepts were developed from the only suitable semi-finished aluminium product available as sheet," says Timm. "In 1982, Audi had to determine whether to develop aluminium as a body material – and, after analysis, we decided that it was worthwhile, but only if we could deploy it in all semi-finished forms. Subsequently, Audi did pioneering work in the areas of thin-walled ductile die-castings and extrusions with Alcoa."
Initially, Audi used small castings, but has long since moved on to multifunctional, large structural body elements. "The ASF [Audi space frame] concept has many advantages: castings and extrusions make it possible to create multifunctional geometries, to transfer bionic principles with better lightweight performance, and to place materials in exactly the place that function demands. It also allows for a reduction in the number of parts.
"Through the use of semi-finished castings and extrusions, ASF also enables better usage of the available package, in terms of stiffness and crash-management. Audi believes ASF delivers the best lightweight performance for each body function. And, in production, the level of automation is comparable to that of a steel body."
Although aluminium is currently the preserve of relatively high-end, low volume prestige cars, Timm doesn't see this as always being the case – especially when hybrid structures are factored in. "For many reasons, it makes good business sense to introduce new technologies top-down, and this is also true for ASF. However, the current A4 and A6 model ranges already include some ASF components and the amount will increase in the future," he says.
And he adds: "The state of the art in aluminium technology suggests that further improvements are to be expected. There will also be an increase in the use of hybrid structures, [because] they make it possible to apply the correct material, the smallest amount and at the best place... We have also optimised our processes and that has enabled significant cost reductions. We remain focused on sensible composite developments, which bring additional lightweight potential, and on better joining technologies via improved industrialisation."
Finally, Timm is at pains to reject any notion that aluminium limits a car's appeal: "It's true that the material properties of sheet steel are better for forming and for creating sharp creases. However, Audi has built tremendous know-how. Just look at the sharp design creases on the new A8 and R8, or at the feather edges on the TT."
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