Audi’s advert for their A6 is really beautifully made…
Suppose you could make metal do anything you wanted,
use it in ways no one thought possible,
at Audi that’s what we do,
the new Audi A6 with Aluminium-hybrid body,
engineered for a lighter touch.
The way the metal forming is done in the advert is really nice, just shaping the parts by hand, just like the clay model can be formed when producing models of the car.
The technology is interesting, and challenging, a combination of aluminium and steel parts are used to make the car body. About 20% of aluminium by weight of the car body is aluminium, that means about 40% by volume. Non-load bearing parts such as body panels are aluminium (which benefit from good stiffness/weight ratio). All of the car body is made from cold formed and warm formed steels as in conventional car body. Interesting, aluminium sections seem to be present as side impact bars and bumper. From the advert you might be left with the impression that the whole body is aluminium, or that this is something that would be desirable, especially confusing since ‘hybrid’ is also now commonly used to refer to automobiles which use combinations of different power sources for the engine.
This video shows which parts of the car body are aluminium and steel.
However these cars overall are not much lighter due to the use of aluminium. From the previous model of A6 the weight saving is 30 kg, the weight if the total car is 1575 kg unladen or 2,155 kg gross weight (figures for 4 door 2.0 diesel). I want to look up the weight of Audio A6 since they are first introduced, that’s because in all cars there has been a trends towards increasing weight, despite all the advances in decreasing the weight of the car body.