10/25/2010 8:29:00 AM
NEWS BRIEFS
Alcoa’s Bobtail Fasteners Boosts U.S. Army Vehicles Fuel Efficiency
Artist’s concept of FEGVD
Alcoa Defense has applied innovative technology it developed for high-performance cars and the aerospace market in a project for the U.S. Army showcasing the ability of aluminum to make the next generation of military vehicle lighter, faster, stronger – and more fuel efficient.
Many structural components of the Army’s Fuel-Efficient Ground Vehicle Demonstrator (FED) vehicle are joined with Alcoa’s Bobtail fasteners, which deliver strong joints without compromising the integrity of the materials, which can occur with conventional welding techniques. In addition, they enhance long-term vehicle durability by maintaining joint strength when absorbing sudden impacts.
The FED is built around an aluminum structure by Alcoa that will make the vehicle up to 10 percent lighter than a comparably sized steel vehicle and reduce fuel consumption by 6-7 percent because the lighter vehicle frame enables a lighter engine, driveline and chassis.
The FED project was launched by the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC) in 2008 to develop a prototype vehicle that would showcase fuel efficient technologies, while maintaining the vehicle’s performance, payload capacity and protection of soldiers.
“If the Army, which operates the world’s largest fleet of ground vehicles, can improve fuel efficiency by just one percent, it will result in 6,000 fewer soldiers being put at risk by driving highly targeted fuel convoys in combat locations,” the military stated.
“Lightweighting” military vehicles via aluminum structures also enhances performance, which is why platforms that traditionally require maximum speed and agility, such as airplanes and sports cars, incorporate many aluminum technologies that originated with Alcoa.
“FED represents the first time we have been able to integrate a comprehensive suite of Alcoa’s lightweighting technologies into one vehicle,” said Alcoa Defense President Dave Dobson. “We are excited to have the opportunity to showcase all of our technologies for making vehicles lighter, faster and stronger in one groundbreaking platform.”
In addition to a welded aluminum spaceframe, other Alcoa innovations on the FED vehicle include.
– An interchangeable aluminum blast and brush shield reduces curb weight.
– Instead of a conventional chassis design with frame rails on each side of the vehicle the FED cab is integrated directly into the front and rear chassis modules without frame rails.
– To increase survivability in combat environments, the FED vehicle features Alcoa’s CR56 aluminum alloy armor in both integral and appliqué (add-on) armor applications, providing excellent ballistic and blast performance protection.
– To reduce weight and increase payload, new forged aluminum wheels were added to the FED vehicle.
Pioneered by Alcoa on the Mine-Resistant Ambush-Protected All-Terrain Vehicle by Oshkosh, the FED will feature aluminum suspension components and mounting structure that can withstand harsh environments and difficult terrain.
Alcoa also used friction stir welding, a specialized welding technique which improves quality by reducing weld-induced distortion, to join several aluminum alloys.
The FED is scheduled to debut at the Association of the United States Army (AUSA) Winter Symposium and Exposition in Ft. Lauderdale, FL. Web: alcoa.com ©2010 GlobalFastenerNews.com
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