Joining Techniques Like Welding in Lightweight Material Structures

2022 ◽  
pp. 121-152
Author(s):  
Aytekin Ulutaş
Keyword(s):  
Automotive Industry ◽  
Fuel Economy ◽  
High Volume ◽  
Body Structure ◽  
Lightweight Materials ◽  
Performance Targets ◽  
Industrial Use ◽  
Industry Needs ◽  
Metallic Panels ◽  
Car Body Structure

In order to take more stringent measures in fuel economy and achieve the determined performance targets, the automotive industry needs to reduce the weight of the vehicles it produces. For this reason, all automobile manufacturers have determined their own strategies. Some manufacturers use lighter aluminum, magnesium, and composite components in their cars. In this study, the joining techniques of lightweight materials such as welding and the processes of their industrial use have been examined. There is currently no single technology that can combine all metallic panels in a car body structure. However, it is known that various joining technologies are used together. With the potential to combine certain combinations of steel and aluminum, manufacturers and scientists continue to work to identify technologies with the highest potential for lightweight joining and put them into use in high-volume automobile production. Therefore, it is important to examine the weldability of light materials such as magnesium, titanium, and aluminum.

Investigation on Mechanical Behavior of Clinched Joint Using Extensible and Flat Die Techniques

2016 ◽  
Author(s):  
Xiaolan Han ◽  
Shengdun Zhao
Keyword(s):  
Tensile Strength ◽  
Shear Strength ◽  
Aluminum Alloy ◽  
Magnesium Alloys ◽  
Automotive Industry ◽  
Weight Reduction ◽  
Structure Optimization ◽  
Body Structure ◽  
Lightweight Materials ◽  
Mechanical Clinching

Lightweight materials, manufacturing technology and the car body structure optimization are the three main approaches to achieve the lightweight constructions. The lightweight materials, such as aluminum or magnesium alloys, are widely utilized in the automotive industry for the weight reduction. Mechanical clinching is used to connect the lightweight materials. In this study, the sheets were joined by the extensible die clinching and flat-clinching. The tensile strength and shear strength of the aluminum alloy 5052 were investigated by the two different tools. Compared with the extensible die clinching, both the tensile strength and shear strength of the clinched joint produced with flat-clinching is higher. And the tensile strength of the clinched joint is up to 54% higher than that of the extensible die clinching.

Microstructure of an extruded rapidly solidified Al-8Fe-2Mo alloy

1986 ◽  
Vol 44 ◽  
pp. 548-549
Author(s):  
W. T. Donlon ◽  
J. E. Allison ◽  
S. Shinozaki
Keyword(s):  
Electron Microscopy ◽  
Automotive Industry ◽  
Fuel Economy ◽  
High Strength ◽  
Al Alloys ◽  
Light Weight ◽  
Thin Sections ◽  
Strength And Durability ◽  
Rapidly Solidified ◽  
Whitney Aircraft

Light weight materials which possess high strength and durability are being utilized by the automotive industry to increase fuel economy. Rapidly solidified (RS) Al alloys are currently being extensively studied for this purpose. In this investigation the microstructure of an extruded Al-8Fe-2Mo alloy, produced by Pratt & Whitney Aircraft, Goverment Products Div. was examined in a JE0L 2000FX AEM. Both electropolished thin sections, and extraction replicas were examined to characterize this material. The consolidation procedure for producing this material included a 9:1 extrusion at 340°C followed by a 16:1 extrusion at 400°C, utilizing RS powders which have also been characterized utilizing electron microscopy.

Improved Roller Hemming System for High Volume Part Production

2011 ◽  
Vol 473 ◽  
pp. 168-175 ◽  
Author(s):  
Martin Zubeil ◽  
Karl Roll ◽  
Marion Merklein
Keyword(s):  
Strain Rate ◽  
Surface Quality ◽  
Automotive Industry ◽  
Dimensional Stability ◽  
Cycle Time ◽  
High Volume ◽  
Non Linear ◽  
Part Production

Roller hemming is usually applied for hang-on-parts such as hoods, doors or trunk-lids which all have complex non-linear geometries. The flange is often hemmed along both surfaces and edges which have 3D curvilinear shapes. Minimization of hemming defects and the requirement to improve cycle time of the roller hemming process are essential for roller hemmed hang-on-parts in the automotive industry. Different systems such as the driven roller hemming provide the possibility to increase the strain rate without loosing surface quality and dimensional stability. Investigating the influence of friction during roller hemming, results will give an understanding of the advantage for mentioned roller hemming systems.

Vibration Damping of a Flexible Car Body Structure Using Piezo-Stack Actuators

2008 ◽  
Vol 41 (2) ◽  
pp. 8287-8292 ◽  
Author(s):  
Martin Kozek ◽  
Christian Benatzky ◽  
Alexander Schirrer ◽  
Anton Stribersky
Keyword(s):  
Vibration Damping ◽  
Body Structure ◽  
Car Body ◽  
Car Body Structure

Lightweight Design of Car Body Structure

2013 ◽  
Vol 7 (1) ◽  
pp. 105-110
Author(s):  
Guo-sheng Zhang ◽  
Jing-hong Li ◽  
Hui-qi Shi ◽  
Wei-liang Dai
Keyword(s):  
Lightweight Design ◽  
Body Structure ◽  
Car Body ◽  
Car Body Structure

1310 Application of FOA to the development of 1BOX-car body structure with various types

2005 ◽  
Vol 2005.15 (0) ◽  
pp. 131-133
Author(s):  
Hiroshi Kamiya ◽  
Kouji Matsumoto ◽  
Hiroshi Okumura ◽  
Hidekazu Nishigaki ◽  
Tatsuyuki Amago
Keyword(s):  
Body Structure ◽  
Car Body ◽  
Car Body Structure

A Preliminary Study of an Inter-Cooled and Recuperative Microgasturbine Below 300 kW

2002 ◽  
Author(s):  
Kenjiro Takase ◽  
Hideo Furukawa ◽  
Kimiaki Nakano
Keyword(s):  
Automotive Industry ◽  
Gas Turbines ◽  
Lower Cost ◽  
High Volume ◽  
Additional Benefit ◽  
Specific Power ◽  
Manufacturing Costs ◽  
Fuel Flexibility ◽  
Commercial Markets ◽  
Preliminary Study

During the last few years, a number of small microturbines (<100kW) have been tested in commercial markets. These microturbines have demonstrated low emissions, increased fuel flexibility, and reasonable durability. However, if these microturbines are to compete economically with larger gas turbines and reciprocating engines, manufacturing costs will need to be significantly reduced and thermal efficiencies will need to be increased. A preliminary study has been completed that evaluated larger and more efficient microturbines (∼300 kW) that operate at higher pressure ratios based on an intercooled and recuperated cycle. The thermal efficiency of the proposed concept increases to 34–37% and is competitive with larger gas turbines and similarly rated diesel engines. Two-stage turbocharger compressors and intercoolers that were developed by the automotive industry for high volume manufacturing will further improve the specific fuel consumption and specific power of this proposed microturbine concept. An additional benefit of the higher pressure, intercooled cycle is that the temperature of the exhaust gases exiting the turbine and entering the recuperator is significantly lower facilitating the use of lower cost materials in the recuperator.

A Study of Car Body Structure to Reduce Environmental Burdens

2003 ◽  
Author(s):  
Shoji Kojima ◽  
Yasuaki Ohmi ◽  
Eizaburo Nakanishi ◽  
Takao Mori
Keyword(s):  
Body Structure ◽  
Car Body ◽  
Environmental Burdens ◽  
Car Body Structure
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