Synopsis:The overall obstacles to lightweight sheet metals application in vehicles are briefly reviewed in this paper with particular emphasis on sheet metal forming problems. Results of a survey indicate that sheet forming is the largest barrier to further high strength steel application; however, for sheet aluminum, cost and welding difficulties are as significant obstacles as the important sheet forming problems. Reduced stretchability and sharp radii sensitivity for both classes of materials are the major limitations and these cause a wide variety of independent failure modes in sheet forming.The overall advantages of the application of these materials are very briefly reviewed. Four areas of progress towards overcoming the forming problems are discussed: (1) materials characterization, (2) improved procedures and guidelines, (3) new forming processes or approaches, and (4) improved materials. Progress in all areas has been highly useful in achieving increased application of the new li ghtweight sheet metals and the continued importance of new approaches (or processes) to sheet forming is highly likely. Such progress will be essential to the continued realization of the significant benefit of lightweight sheet metal utilization in vehicles: cost-effective decreases in fuel consumption.
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