Our client, an automotive assembly plant, was using a 1215 steel alloy to machine and form the transmission fluid hose fitting. The steel fitting required a complicated and time intensive assembly during installation. In addition, the 1215 steel alloy did not provide very good corrosion resistance, making service costs more time consuming. Installation costs had to be reduced, while corrosion resistance had to be increased.
Alcoa Global Cold Finished Products examined different materials that would better suit the fittings. Alcoa Deltalloy® 4032 fit the re-engineering challenge. Alcoa Deltalloy® 4032 was selected over common 6xxx aluminum alloys for its superior corrosion resistance and formability for use in a quick connect transmission fluid hose fitting. Initially, Alcoa Deltalloy® 4032 was only available in the - T651 temper, which proved not to be ductile enough to withstand the aggressive forming process. In early customer trials, this led to periodic cracking and undesirable surface finish during the forming operation. Alcoa's application engineer suggested a more ductile - T451 temper to provide the needed formability for the flaring operation. Also, a customized manufacturing practice was implemented to provide the necessary metallurgical structure for a smooth finish during forming, thus ensuring a leak free connection. Without enhancing the formability and providing improved corrosion resistance, the application would not have been a success.
The increased formability enabled ease of installation of the fitting at the automotive assembly facility and reduced installation costs with the quick disconnect design. The additional corrosion resistance provided ease of repair of transmission fluid coolers after service. Alcoa Deltalloy® 4032 also provided weight savings over the incumbent steel.
Through a combination of chemistry control and specialized cold finished manufacturing processes, Alcoa Global Cold Finished Products was able to meet the challenge, lowering installation costs and improving corrosion resistance.
