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HALO system processing
Project type
Course Project
Date
Feb 2021
Location
Shanghai, China
Role
Background research; Titanium material basic force analysis and selection; Welding process selection
The Halo system is a safety feature designed to protect Formula One drivers from fatal injury caused by rollover accidents. It consists of a titanium structure that sits above the car's cockpit, supported by a single vertical pylon and mounted to the car's survival cell and cockpit surround.
The main goal of this project is to select the material and design a factory process for manufacturing the Halo system using titanium alloy Ti 6Al-4V. The process includes pre-machining and welding, as well as load testing to ensure the Halo meets safety requirements. The electric bending machine is used to achieve a proportional bend, while a 5-axis milling machine is used to create the complex shape of the V transition.
While the Halo system was ultimately chosen by the FIA, alternative solutions such as the Aeroscreen and Shield were also considered.
