Front and rear
Crash management in front/rear is one of the major applications for aluminium extrusions in the automotive industry. Excellent energy absorption and the weight saving achieved especially with high-strength alloys of the 7xxx series are the main reasons.
By using extrusions, the material can be distributed where it is most needed at the cross section. This enables us to design systems that fit exactly to the specific requirements.
In Front/Rear
- Crash boxes are easily replaceable low-cost units that prevent damage to the car body/chassis structure in medium-speed impacts, hence reducing repair and insurance costs
- The main functions of bumpers are to reduce the damage to exterior components in low-speed impacts, to keep the front structure together in high-speed impacts and to provide stiffness to ensure comfort (NVH), ride and handling under operating conditions
- In a severe frontal impact, optimum crash performance presumes that the beam and boxes provide the function of transferring the impact load into and between the longitudinals and thence into the rest of the structures, such as A-and B pillars, sill and roof structure
We are the global leader in crash management systems in aluminium and develop and manufacture bumper beams for almost all major OEMs. In 2006, we delivered about 7.5 million bumper beams as single parts or as part of a crash management system to our customers worldwide, the majority of them to Western Europe.
Concept development
We are developing the crash management system tailor-made to customer needs. Our development starts with the customer packaging and accompanying requirements. Based on that, we develop concept ideas, while our further work includes CAD, FEA work, prototyping, crash-testing and the complete serial tooling.
Alloys
The alloys we are using are mainly specifically developed alloys of the 7xxx series in order to achieve maximum weight reduction and energy absorption. Where appropriate, we even use cost efficient 6xxx alloys.
Facilities and processes
In production, we control the whole value chain from billet casting over extrusion to forming, machining and assembly. After casting and extrusion, stretch-bending is the main process for our bumper beams. The stretch-bending process ensures closer tolerances of the product than those that can be achieved with simpler press-bending.
Our plants dedicated to crash management are located in Raufoss (Norway), Louviers (France), Skultuna (Sweden) and Holland (MI, US). The Competence Centre for Crash Management is also located in Raufoss/Norway.
