Page 6 - Mortor Fan illustrated

ALUMINUM Smart Developments

Case Study Evolving Joining Technologies for Aluminum

03 03

LEXUS LS

f Toyota’s LSW (laser The aluminum alloy doors of the Lexus LS are a showcase for joining technologies. Motonobu Hachino
screw welding) offers In addition to the hemming which is regularly used for the outer and inner panels,
various advantages such i Fine welding beads are the appropriate technologies used for each job include LSW, SPR, FSW, FSSW, Manager
as increased productivity produced by laser seam welding. and laser welding. Tailored blanks are also used. The materials technology, forming Development Department II,
Research & Development Division,
and short pitch welding. Laser welding suppresses UACJ Corporation
thermal distortion to a minimum. technology and joining technology established through the manufacture of the
aluminum alloy doors for the LS will be applied to future models. UACJ’s Motonobu
Hachino says that he is eagerly looking forward to that.

fh This photograph shows how FSW/FSSW
g SPR (self-piercing
riveting) is frequently used deeply the alloy was drawn to
produce this inner door panel.
because aluminum has 6000 series aluminum alloys are Friction stir welding (FSW) is a joining technology that involves the
high thermal conductivity use of a tool with a pointed revolving tip that is pressed against
and it is slightly difficult to used for both the inner and outer the metal, which is then softened by friction-generated heat.
door panels of the LS.
spot weld. This plasticized material is used to join pieces of metal together.
This method has many benefits, including low levels of distortion Motor Fan illustrated
and residual stress, and less significant reduction in strength
Motor Fan illustrated
when exposed to heat.

INNER OUTER
6000 6000 Evolving aluminum joining technologies
series series ALUMINUM Smart Developments
Various types of joining technologies for aluminum have been developed and put to practical use,
ranging from MIG welding and YAG laser welding to mechanical joining and binding.
The AUDI A8 adapts different types of joining tools and methods, such as flow drill screws, punch
rivets, mechanical clinching, MIG welding, and binding according to the points of application.
ALUMINUM Smart Developments
06 Resistance spot welding Laser beam welding Adhesion 07
Resistance spot welding (aluminum/aluminum) (aluminum/aluminum)
(steel/steel)

MIG welding
Flow drill screws

Semi-hollow punch rivets

fh The part resembling a strip is Friction Element Welding
h With the LS, the frame is formed as a where FSW (friction stir welding) for
single unit. The outer door panels are tailored blanks has been conducted.
reinforced by welding sheets of a different
thickness using TB (tailored blanking). YAG laser welding

MAG welding
(steel/steel) Roller hemming Clinching Punch rivets

PHOTO: AUDI/MFi