Project Brief
Motor Vehicle Manufacturing Technology (September 1995)Advanced Welding Technology for Structural Automotive ProductsDevelop a versatile manufacturing process that combines a precision metal-forming step with an unconventional welding method, capable of joining dissimilar metals, to build lower-cost, lower-weight aluminum and steel load-bearing structures such as car and truck frames. Sponsor: Dana Corporation Structural Solutions Group (formerly Dana Corp.)Parish Light Vehicle Structures DivisionPO Box 13459 -- Robeson & Weiser Streets Reading, PA 19612
Reducing the weight of cars has been a major strategy for increasing fuel efficiency. Most auto makers believe that the present generation of vehicles has achieved near-optimal weight reduction with the choices of materials and manufacturing methods currently employed. Further weight reductions will require the introduction of new lighter-weight materials such as aluminum and/or new manufacturing processes that require lesser amounts of traditional materials such as steel. The Dana Corporation's Parish Light Vehicle Structures Division proposes to combine both approaches in a manufacturing process for a wide variety of lower-cost and lighter components and structures such as load bearing frames of cars and light trucks. The process begins by subjecting preshaped aluminum and steel tubular stock to high pressure within precision die cavities machined directly from computer-aided design files. The hydroforming method leads to more precisely fitting structural components requiring little overlapping or fill material for the subsequent welding steps. The welding method, to be co-developed with the Spicer Driveshaft Division of Dana, will be achieved with an innovative welding process capable of rapidly joining dissimilar metal substrates. Compared to conventional welding techniques such as electrical resistance spot welding or metal deposition welding, in which additional metal is needed to achieve bonding, Dana's process will reduce greatly the amount of joining material and the time required to perform it. Factory floor versatility will be built into the overall process with a repertoire of tubular segments that can be mixed readily and matched to construct frames and other structures for a large range of vehicular models. This new technology will streamline the manufacturing process, thereby allowing auto manufacturers to respond more quickly to consumer preferences and competitive pressures. In addition, it will reduce weight and increase fuel economy.
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