7xxx Series Aluminum Alloys Research Articles

Sensitization of 5xxx Series Aluminum Alloys explored with an adapted JMAK model for phase evolution and ultrasonics

Abstract Phase transformations in 5xxx series aluminum alloys (AA) during sensitization impact the propagation of ultrasound through these materials in a quantifiable way. The effect of phase evolution on three experimentally measured acoustic parameters (longitudinal wave speed, shear wave speed, and longitudinal wave attenuation) in sensitized 5xxx AA was analyzed under the framework of the Johnson-Mehl-Avrami-Kolmogorov model. The phase transformation rate constant, k, and the Avrami exponent, n, were determined from fitting the experimental data with a developed model. At saturation, which is independent of k and n, the wave speed values agree with those measured individually for each phase. The k value for shear speed is higher for AA5456 than for AA5083, reflecting that AA5456 reaches full sensitization earlier (per standard, the amount of Mg is higher is 5456 than in 5083). The k values for both shear and longitudinal wave speed match the Arrhenius equation for literature NAMLT data (for a given alloy type and heat treatment), the current data extending the existing range to higher temperatures. The difference between the effective k values obtained from the longitudinal-wave attenuation-coefficient and wave-speed data reflects the important contribution of scattering to acoustic attenuation in a sensitized material. The values of n in the 1 to 2 range indicate a combination of 1D and 2D growth, pointing to beta phase growth mostly at grain boundaries and at their intersections. At the highest processing temperature, n is higher, suggesting partial occurrence of 3D growth.

Investigation of grain boundary segregation evolution and corrosion behavior in 7050 aluminum alloy under oscillating laser melting

The weld structures of 7xxx series aluminum alloy have been applied on aerospace, rail transport, petrochemical engineering, and other fields. However, the corrosion resistance of welded joint is usually reduced due to the microstructrue morphology of fusion zone (FZ). In this study, five oscillating modes were used to melt 7050 aluminum alloy, and the relationship between the microstructure and corrosion properties of different modes of FZ was analyzed. In particular, morphology observation, electron backscattered scattering detection (EBSD) test and phase analysis were carried out by SEM and TEM, and the grain boundary segregation, element distribution and grain characteristics under different modes were analyzed and compared. The relationship between laser beam oscillation mode, microstructure of FZ and corrosion resistance was established. It is concluded that the potential disparity between the precipitated phase and the grain, engendered by the variance in the concentration of the precipitated phase and the content of low-potential elements within the phase, exerts a decisive impact on the corrosion resistance of the material. The purpose of this study is to provide a new way to improve the corrosion resistance of 7050 aluminum alloy laser machined parts, and to meet the industrial needs of aerospace and other fields to the maximum extent.

Simulating hydrogen-controlled crack growth kinetics in Al-alloys using a coupled chemo-mechanical phase-field damage model

Environmentally Assisted Cracking (EAC) of 7xxx series aluminium alloys involves interactions between multiple physical phenomena, which ultimately influence the in-service life of critical components. In this work, we present a new model to study EAC in 7xxx series alloys, which is implemented in the multiphysics simulation framework, DAMASK. The chemo-mechanical model couples crack tip hydrogen generation, resulting from surface oxidation, and transport, with crystal-plasticity-governed intergranular crack propagation, through the microstructural trapping of hydrogen at dislocations, grain boundaries (GB), and crack tip stress fields. Large-scale simulations with realistic grain structures have been performed to provide novel insight into the dominant rate-controlling processes associated with intergranular EAC in 7xxx series aluminium alloys. The model was able to reproduce experimentally measured crack velocities under different loading conditions. Parametric studies indicate that, in addition to the GB network morphology, the crack growth rate was controlled by hydrogen generation at the crack tip with long-range diffusion having negligible influence. Additionally, the total hydrogen generated through crack tip oxidation appears to be more significant than the peak generation rate.

Laser Directed Energy Deposition Additive Manufacturing of Al7075 alloy: Process Development, Microstructure, and Porosity

7xxx series aluminum alloys are priority materials adopted in aerospace because of their lightweight property and excellent mechanical performance. The combination of lightweight material and additive manufacturing techniques can significantly promote lightweight design in many industries. This study developed the optimal process for manufacturing Al7075 alloy by laser-aided directed energy deposition and revealed the material properties of the as-deposited Al7075 specimens. Firstly, single-track experiments were conducted by varying laser power, printing speed, and powder delivery rate in broad ranges. Results indicated that the printing speed and powder delivery rate impact the surface finish and shape of single-track beads considerably. Block specimens printed with the optimal parameters selected from the single-track experiments present crack-free quality and have a high relative density of up to 99.89%. Second phases with rich Cu, Mg, and Zn elements along the inter-dendritic regions and grain boundaries were observed from the microstructure inspection. The composition of zinc in the deposited samples is lower than usual, which leads to a relatively low microhardness.

Grain boundary sensitization kinetics of cold-rolled Al–Mg alloys

As super-saturated solid solutions of Al-Mg, 5XXX series aluminum alloys are susceptible to sensitization via intergranular precipitation of the anodic β-phase, which promotes intergranular corrosion, exfoliation and stress corrosion cracking under environmental conditions. This study presents important updates to a Johnson–Mehl–Avarami–Kolmogorov (JMAK) type model for low-temperature sensitization, correlating the intergranular corrosion response to impingement of locally sensitized regions surrounding discrete β-phase grain boundary precipitates. It is demonstrated that the sensitization response of these alloys can be approached as a combination of two independent contributions: the geometric configuration of grain boundaries passing through the microstructure that are most prone to sensitization, and the rate that these boundaries sensitize due to the formation of the β-phase. This allows for the large sensitization response variations found between nominally identical materials produced by different suppliers, which originate due to a lack of constraints within current cold-rolled plate tempers, to be removed as a sample-dependent linear scaling factor that is separate of the rate kinetics. The JMAK model describes the kinetics of 5xxx series sensitization with excellent accuracy across all data available in the literature. The results of the model imply that sensitization at environmental temperatures proceeds via a site-saturated process, with the β-phase forming on a set density of preferential nucleation sites. It is shown that site-saturation allows for extension of the JMAK model to non-isothermal aging profiles and supports a diffusion pathway dominated by pipe diffusion to the interface followed by precipitate growth via the collector plate mechanism.

An investigation on effect of tramp elements and solidification processing on homogenization kinetics of AA 7xxx series aluminum alloys

AA 7068 Aluminum alloy is produced via conventional solidification (CS) and controlled diffusion solidification (CDS) processing and homogenized at 450 °C for 6 and 12 h. Optical microscopy (OM) and scanning electron microscopy (SEM) equipped with an energy dispersive x-ray spectroscope (EDS) were used to examine the as-cast and homogenized samples. It was found that although the CS sample is more chemically homogenized in the as-solidified state, the CDS sample exhibits a higher homogenization rate during the treatment. The calculated phase diagram (CALPHAD) methodology was employed to study the effect of silicon and iron on the solidification path and homogenization of the alloy. Silicon consumes magnesium atoms on the surface of the α-Al phase to form the Mg2Si phase. Therefore, the magnesium concentration on the α-Al phase required for the formation of the σ phase must be increased. Calculations shows that all the Mg atoms at this stage are completely supplied from the bulk of the αAl phase. It can be hypothesized that during the last stage of solidification, a solid/liquid diffusion couple can be created between the primary αAl and the remaining liquid for several minutes (4 min at a cooling rate of 0.2 oC/s). As a result of the activation of this couple, the Mg atoms diffuse from the α-Al bulk to its surface, and vacancies diffuse from the surface to the bulk, forming a line of Kirkendall voids. With CDS processing, the surface of the primary phase is less Mg-concentrated than that in the CS process and this significantly reduces the formation of the Mg2Si phase. Conversely, the vacancy and Mg concentration of the αAl phase in CDS is higher than that of CS and this lets other alloying elements other than Mg diffuse to the primary phase, decreasing the homogenization time. The presence of Si in the alloy leads to the formation of the Mg2Si phase, which significantly reduces the final Mg concentration in the α-Al phase after full homogenization. In the pure alloy, the Mg concentration is 2.42 wt%, while in the FeSi-containing alloy, it is reduced to 1.58 wt% due to solid solution and dispersion strengthening mechanisms. Through CDS processing, the negative impact of Si can be reduced by disrupting the mechanism of Mg2Si formation.

Microstructure Evolution and Forming Characteristics of Post-Weld Composite Treatment of 6061 Aluminum Alloy Tailor Welded Blanks

The mechanical properties and cross-sectional geometric dimensions of the fusion zone (FZ), heat affected zone (HAZ), and base metal (BM) of 6xxx series aluminum alloys are inconsistent after filler wire welding, which reduces the formability of aluminum alloy tailor welded blanks (TWBs). This paper proposes a post-weld cold rolling-solution heat treatment (PWCR-SHT) composite process, and the effects of weld excess metal, plastic deformation, and SHT on the formability of aluminum alloy TWBs are studied. The results show that the PWCR-SHT composite process eliminates the weld excess metal and internal pores, reduces the stress concentration at the weld toe, eliminates the local strain hardening behavior, and causes recrystallization in the FZ region. The cupping value of aluminum alloy TWBs using SHT is 105% of BM, in comparison, the cupping value of aluminum alloy TWBs using the PWCR-SHT composite process is 119% of BM, which is the result of the combined effect of geometric dimensions consistency and mechanical properties consistency.

Corrosion behavior of dissimilar Al–Mg–Si alloys joint welded under hybrid CMT-laser oscillation welding

As the corrosion behavior of 6xxx series aluminum alloys depends on composition and microstructure, the microstructure and corrosion behavior of 6082 and a new 6xxx aluminum alloy weld joint are investigated under a standard corrosion test in this study. These results show the asymmetrical welding joint structure and a distribution of corrosion severity across the weld joint. Substantial differences were observed in the size and distribution of Mg2Si particles and Fe-bearing intermetallics in various regions of the weld joint. It was found that the equiaxed grain zone on new 6xxx aluminum side is not most susceptible to corrosion, contrary to previous results, but the narrow partially melted line on 6082 side is. Not all corrosion induced by Fe-bearing intermetallics originates from the Al matrix, adjacent Fe-bearing intermetallics and Mg2Si could also form galvanic microcells, resulting in preferential dissolution of Mg2Si over the Al matrix.

Evaluation of Vibration Damping Enhancement in Laminated Aluminum Sheets for Automotive Application.

In this research, the vibration damping characteristics of the laminated aluminum sheets (LAS) were evaluated in a sheet specimen and an automotive dash panel and compared with those of the monolithic aluminum sheet (MAS). The LAS was fabricated with two 5xxx series aluminum alloy (AA) sheets (AA5052-O) with a thickness of 0.7 mm by inserting an acryl-based adhesive in between. The automotive dash panels were manufactured by multi-step stamping processes for the LAS and the MAS with a similar thickness. The shaker vibration test in a sheet specimen and the impact hammer test in an automotive dash panel were conducted to measure the frequency response function (FRF) of LAS, compared with those of MAS. The results show that the frequency response function made by the LAS has less noise and fluctuation than that of the MAS in a sheet specimen and an automotive dash panel. The damping ratios in a sheet specimen and an automotive dash panel made by the LAS have higher values than those of the MAS. This proves that the LAS has better vibration damping characteristics and a larger damping effect than the MAS in a sheet specimen and an automotive dash panel.

Quality Prediction Algorithm for Flow Drilling Screw Joining of 590 MPa High-Strength Steel and 6xxx Series Aluminum Alloy

Flow drilling screw (FDS) process is applied to various components such as car bodies and battery cases due to its advantage of enabling one-sided joining. Various studies have been conducted on the correlation between monitored process parameters and joint quality. These correlations suggest the potential for non-destructive classification or prediction of joint quality using process monitoring signals. In this study, the effect of FDS process parameters on joint quality was analyzed, and a decision tree-based quality prediction model for classifying joint quality was developed. The material combination consisted of a 1.8 mm thick SGAFC 590DP as the upper plate and a 3.0 mm thick Al 6061 as the lower plate. To develop the joint quality prediction algorithm, the effect of process parameters in each process step on joint quality was analyzed. It is used as input data to identify various features. The output data were generated by classifying the products into three categories from class 0 to class 2. Based on the extracted feature data, a machine learning algorithm was trained to develop the joint quality prediction model.

Recent progress of Al–Mg alloys: Forming and preparation process, microstructure manipulation and application

In the global pursuit of energy conservation, reduction in consumption and emissions, as well as lightweighting, 5xxx-series aluminum alloys have emerged as a promising lightweight and high-strength material with a wide range of applications in aerospace, transportation, building structures, medical devices, and more. However, it is worth noting that 5XXX-series aluminum alloys belong to a category of non-heat-treatable reinforced aluminum alloys with limited means of enhancing their properties through heat treatment. Consequently, the development of high-performance 5XXX-series aluminum alloys poses a significant challenge. This paper provides an overview of the research progress on 5xxx-series aluminum alloys while discussing the current state of research regarding the influence of microalloying elements on their microstructure and properties. Furthermore, it elucidates the emerging trends in synergistic regulation between deformation processes and heat treatment processes for enhancing organizational refinement and improving alloy properties. Additionally, this study analyzes the reinforcement mechanism responsible for the exceptional properties exhibited by 5xxx-series aluminum alloys. Lastly, it discusses the exceptional properties exhibited by 5xxx-series alloys along with their primary areas of application. The findings presented herein can serve as a valuable reference for future advancements in advanced high-performance 5xxx-series aluminum alloys.

Development of Low-Pressure Die-Cast Al-Zn-Mg-Cu Alloy Propellers-Part Ⅰ: Hot Tearing Simulations for Alloy Optimization.

Recent advances in the leisure boat industry have spurred demand for improved materials for propeller manufacturing, particularly high-strength aluminum alloys. While traditional Al-Si alloys like A356 are commonly used due to their excellent castability, they have limited mechanical properties. In contrast, 7xxx series alloys (Al-Zn-Mg-Cu based) offer superior mechanical characteristics but present significant casting challenges, including hot-tearing susceptibility (HTS). This study investigates the optimization of 7xxx series aluminum alloys for low-pressure die-casting (LPDC) processes to enhance propeller performance and durability. Using a constrained rod-casting (CRC) method and finite element simulations, we evaluated the HTS of various alloy compositions. The results indicate that increasing Zn and Cu contents generally increase HTS, while a sufficient Mg content of 2 wt.% mitigates this effect. Two optimized quaternary Al-Zn-Mg-Cu alloys with relatively low HTS were selected for LPDC propeller production. Simulation and experimental results demonstrated the effectiveness of the proposed alloy compositions, highlighting the need for further process optimization to prevent hot tearing in high Mg and Cu content alloys.

The influence Cl− on stress corrosion of 7xxx series aluminium alloys studied by experimental and simulation technology

The stress corrosion behavior of 7xxx series aluminium alloys in different concentrations NaCl solution was studied, and numerical simulation was conducted in COMSOL Multiphysics based on experimental results. Different stresses were applied on the experiment pieces, the pitting crater deepened with the change of stress level. The corrosion rate increased with the raising stress. There is no positive correlation between stress corrosion degree and chloride ion concentration. The most severe corrosion occurs in 5.0 wt% NaCl solution instead of 6.0 wt% NaCl solution due to the increase of water film conductivity and decrease of solubility of oxygen under high Cl− environment. The finite element model was used to analyze the stress distribution on aluminium alloy surface, to describe the dynamic equation of anodic dissolution of metal due to elastic and plastic deformation. Corrosion occurs mainly in stress concentrated areas. When the stress loading exceeds a certain threshold, plastic strain occurs on the surface of both the specimen and the structural part, the corrosion current density increases instantaneously, and the corrosion behavior in the stress concentration area gradually intensifies. The survey can provide practical theoretical guidance for predicting stress corrosion and extending the service life of equipment in (harsh) marine environments.

On the mechanisms of charge weld evolution in aluminum extrusion

This study aims to provide new insights into the governing mechanisms of material property evolution within the charge weld zone in the hot extrusion process of aluminum profiles. A set of 6xxx series aluminum alloy tubular profiles was produced through carefully designed industrial experiments of billet-to-billet extrusion. The evolution of material integrity within the charge weld zones was experimentally characterized by microhardness tests, optical microscopy, scanning electron microscopy (SEM), and drift-expansion tests. The experimental analyses reveal that the material integrity of charge welds gradually increases from the onset to the end, primarily driven by the ‘local’ pressure history experienced. Towards the end of the charge weld zone, grooves and holes, and oxide particles gradually vanish, leading to enhanced material integrity. A through-process finite element (FE) model was developed using QForm-Extrusion software to analyze the thermo-mechanical history of charge weld formation, providing a deeper understanding of how material properties evolve and the underlying mechanisms governing this evolution. The model was experimentally validated in terms of the extrusion load and distribution of the charge welds in extruded profiles. Overall, the new insights gained in this study offer valuable knowledge for enhancing the process and quality control in billet-to-billet extrusion, as well as reducing in-process scrap towards more sustainable production of aluminum profiles.

Effect of equal-channel angular pressing on microstructure, aging kinetics and impact behavior in a 7075 aluminum alloy

Among the precipitation hardenable 7xxx series aluminum alloys, AA7075 alloys (one of the most important engineering alloys) due to their low density (lightweight), high toughness and strength, and enhanced fatigue behavior have been used over the years in aerospace, aircraft, automotive, construction and marine applications. In the present study, the influence of the artificial aging through conventional heat treatment (i.e., precipitation hardening) and the thermomechanical treatment (equal-channel angular pressing (ECAP) + post-ECAP aging) on the quasi-static tensile, impact toughness and precipitation behavior as well as on the microstructure of an AA7075 alloy is investigated systematically. The results indicate that the ECAP process as well as post-ECAP aging result in considerably increased strength and hardness of the AA7075 alloys because of the superimposed effects of grain boundary strengthening (Hall-Petch relation), strain hardening (by means of the increased dislocation density) and precipitation hardening (due to the fine precipitates formed in Al matrix). Multi-pass ECAP processing has been found to result in a considerable decrease of the impact toughness (from 15.3 J·cm−2 to 7.6 J·cm−2) associated with the failure mode (i.e., ductile-to-brittle transition) of the AA7075 alloys, whereas the artificial peak aging leads to a marked improvement (∼67 %) in the impact toughness in ECAPed conditions. Moreover, the ECAP process noticeably accelerates the precipitation kinetics of AA7075 alloys: The peak aging time in the ECAPed alloy is reduced significantly – from 30 h to 4 h. The results of the present study provide a deeper understanding of the combination of ECAP and heat treatment, and their effect on the fracture mode and toughness under impact loading, the aging kinetics and the microstructural evolution of an AA7075 alloy.

Texture study of an AA5083 processed by Repetitive Corrugation and strengthening

5xxx series aluminum alloys are widely used due to their corrosion resistance and weldability. These alloys exhibit interesting behavior when subjected to severe plastic deformation (SPD). Different SPD techniques allow the processing of materials in sheet forms, such as Repetitive Corrugating and Straightening (RCS) and Cumulative Roll Bonding (ARB). In this work, sheets of the aluminum 5083 alloy were processed by RCS up to 2 passes. The objective was to study the microstructural evolution of the AA5083 under heat treatment and plastic deformation processes, with the aim of finding a good balance between the yield strength and ductility. The microstructure changes and the mechanical effects of the process were studied by X-ray diffraction, Inverse Pole Figures, EBSD, and tensile test. The results showed the obtention of characteristic recrystallization and deformation textures (cube and brass component); in particular, the brass component decreased to ∼10 % due to the RCS process. The first RCS pass obtained the best balance between yield strength-ductility (σy = 170 MPa and maximum elongation ∼ 8%). With the results obtained, it was concluded that the microstructure and the mechanical properties of the processes alloy were determined by the accumulative dislocations density, which stopped the cube texture progression, microstructure stabilizing the microstructure, regardless of the work hardening.

Numerical Simulation and Machine Learning Prediction of the Direct Chill Casting Process of Large-Scale Aluminum Ingots.

The large-scale ingot of the 7xxx-series aluminum alloys fabricated by direct chill (DC) casting often suffers from foundry defects such as cracks and cold shut due to the formidable challenges in the precise controlling of casting parameters. In this manuscript, by using the integrated computational method combining numerical simulations with machine learning, we systematically estimated the evolution of multi-physical fields and grain structures during the solidification processes. The numerical simulation results quantified the influences of key casting parameters including pouring temperature, casting speed, primary cooling intensity, and secondary cooling water flow rate on the shape of the mushy zone, heat transport, residual stress, and grain structure of DC casting ingots. Then, based on the data of numerical simulations, we established a novel model for the relationship between casting parameters and solidification characteristics through machine learning. By comparing it with experimental measurements, the model showed reasonable accuracy in predicting the sump profile, microstructure evolution, and solidification kinetics under the complicated influences of casting parameters. The integrated computational method and predicting model could be used to efficiently and accurately determine the DC casting parameters to decrease the casting defects.

Predicting the in-plane mechanical anisotropy of 7085 aluminum alloys through crystal plasticity simulations and machine learning

The crystallographic texture of rolled 7xxx series aluminum alloys may lead to mechanical properties anisotropy which undermines the formability and performance of the material. This article aims to explore the quantitative relationship between texture and the in-plane anisotropy of 7085 aluminum alloy. A comprehensive computational method combining crystal plasticity simulation with machine learning and experiment was used to establish an analytical model and train a machine learning model to predict the anisotropy of 7085 aluminum alloys. We first performed a full-field crystal plasticity spectral simulations using fast Fourier transformation (CPFFT) to predict the anisotropy of 7085 aluminum alloy at different annealing times. Then, based on the CPFFT simulation data, the quantitative relationship between texture and the in-plane anisotropy of the r-value was established by using the multiple linear regression and gradient boosting regressor model. The results indicate that CPFFT simulation can effectively capture the influence of texture changes on anisotropy, and the model established through the gradient boosting regressor model is in good agreement with experimental results, providing effective guidance for improving the performance of 7085 aluminum alloy sheets.

Sustainability through Optimal Compositional and Thermomechanical Design for the Al-7XXX Alloys: An ANOVA Case Study

The quest for lightweight, high-performance structural materials for demanding applications such as in the fields of automotive, aerospace, and other high-tech and military industries pushes the boundaries of material science. The present work aims to draw attention to a novel, sustainable manufacturing approach for the development of next-generation 7xxx series aluminum alloys that have higher strength by rejuvenating a sustainable compositional and thermomechanical processing strategy. Our innovative strategy integrates two key synergies: trace hafnium (Hf) addition for microstructural refinement, unique thermomechanical treatment involving cryorolling, and a short annealing method. Experimental results revealed that our base alloy exhibited a 33 µm grain size and impressive initial mechanical properties (334 MPa UTS, 150 HV). Adding 0.6 wt.% Hf and employing 50% cryorolling with short annealing led to a remarkable 10 µm grain size reduction and significant mechanical property leaps. The resulting alloy boasts a 452 MPa UTS and 174 HV, showcasing the synergistic advantageous effect of Hf and cryorolling plus annealing treatment. The developed alloys were compositional- and work hardening-dependent, leading to a rich mix of strengthening mechanisms. Optical and scanning electron microscopy reveal several intermetallic phases within the fcc matrix, wherein the Al3Hf phase plays a key role in strengthening by impeding dislocation movement. In addition to experimental results, a 12-full-factorial design experiment via ANOVA analysis was also utilized to validate the significant influence of Hf and cryorolling on properties with (p-values < 0.05). Among the different parameters, cryorolling plus annealing appeared as the most noteworthy factor, followed by the composition. Using the regression model, the ultimate tensile strength and hardness were predicted to be 626 MPa UTS and 192 HV for an alloy with 0.6 wt.% Hf and 85% cryorolling, which opens a new avenue for ultra-high-strength Al7xxx alloys.

Innovative joining technologies for lightweight material vehicles

The transport industry is one of the most important for society and its economic growth. In Europe, this is especially true for road transport, which is an essential pillar for employment, trade, and economic development. The challenge is to minimize energy and cost and maximize efficiency while ensuring comfort and safety. This is the driving force behind technological progress that with social changes (such as, changing consumer preferences, greater environmental awareness) and political changes is revolutionizing the way people and goods move. Nevertheless, the selection of lightweight materials is negligible; it could involve new manufacturing technologies and joining techniques. Jaguar Land Rover (JLR) has been one of the prominent car producers employing aluminum alloys since 2003. A typical JLR monocoque is characterized by 90% aluminum stampings components made of 5xxx and 6xxx series aluminum alloys. Audi Space Frame (ASF) represents an alternative interpretation of improved lightweight frame architecture, and it is characterized by aluminum for more than 80% with the residual parts in CFRP used for rear panels, tunnel and the components useful to higher torsional stiffness. A 30% weight decrease is reached with respect to traditional steel corresponding elements. This review shows an overview of the challenges and opportunities for automotive body structures in the coming years while maintaining the goal of reducing mass and improving sustainability without increasing costs and impacting safety. This manuscript first evaluates how we can reduce mass in vehicles minimizing the carbon footprint and developing recyclable structures. The potential of new materials will be shown in light of the design constraints and the choice of technology used. The final remarks will discuss opportunities for engineering innovation dictated by this period of great changes and needs.