Page 7 - Mortor Fan illustrated
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ALUMINUM  Smart Developments

 Case Study  Evolving Joining Technologies for Aluminum

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 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
                                                    when exposed to heat.
 Motor Fan illustrated

 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)

                                                                                            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
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