Metals Polymers Ceramics

New Nissan to feature complex aluminum castings The new Nissan GT-R features aluminum inner-door and rear-seat structures made from Alcoa’s proprietary vacuum die casting process (AVDC) at the company’s plant in Soest, Germany. Both components also feature new proprietary alloys developed by Alcoa. The new C-446 alloy, in combination with the unique advantages of the AVDC process, enabled Alcoa to meet their needs. The sports sedan’s rear seat structure also presented its own safety performance challenges, in this case strength and stiffness. Here again, Alcoa’s engineers combined specific AVDC process advantages with another new, proprietary alloy, C-611, to meet Nissan’s specifications. The rear seat structure also provides a weight savings of approximately 25% compared to a conventional steel design. The Nissan GT-R inner door structure is the largest vacuum die casting in the auto industry. In addition to its size, gauge, weight, strength, and deformation demands, the inner door also has some very daunting appearance requirements. Alcoa’s AVDC process provides the company’s structural engineers with the ability to “build in” critical reinforcing ribs where enhanced strength is required, and to “design in” very specific details to help consolidate parts and streamline assembly. For more information: Alcoa, 201 Isabella Street, Pittsburgh, PA 15212; tel: 412/553-4545; www.alcoa.com; www.nissanusa.com.