铝合金车身常见连接工艺

FDS
4. 4 CMT(cold metal transfer)
① 低热量输入，无飞溅，污染小 ② 焊接速度快，热区变形小，可以钢铝混合焊 ③ 焊接强度只有母材70%，焊机区域有应力集中，需要释放
CMT
4. 4 CMT(cold metal transfer)
4. 5 Resistance Spot weld
Resistance Spot Weld
① Widely used in OEM,low cost and high efficiency ( steel body) 广泛用在钢车身上，高效率低成本 ② Short fatigue life and poor appearance 疲劳寿命短，外观质量差 ③ Not commonly used on aluminum body and not feasible for AL-steel mixed body铝车身上用的不多，在 钢铝混合部位无法使用
SPR-1
SPR-2
4. 1 SPR (Self Pierced Rivet)
unacceptable
acceptable
① 2-3 layers connection 2-3层连接 ② Internal defect is not visible unless Slicing 内部缺陷肉眼不可见，只能切片
4. 1 SPR (Self Pierced Rivet)
SPR
① ② ③ ④ Besides Aluminium body , popular mixed steel&Al body , plastic components Cold connection ,no electrical sparkle Longer lifecycle for durability, more impact absorbing Consistent connection appearance
General Joining on Aluminium Body
28/03/2019
1. Why Aluminium body is gaining its popularity?
2. What vehicles use Aluminium parts on body?
3. General Joinings on Aluminium Body
BMW 7 Jaguar XF Ford F150 Benz S-class
129.3 120 112.5 216.6
5719 1043 0 5314
0 0 12 0
564 2794 2270 724
154 0 196 0
Benz S-class
Thank You
28/03/2019
Blind Rivet
4. 7 laser welding
A Laser weld(no solder needed , burning through parts) Laser Weld
B
Laser brazing(solder needed)
Laser Brazing A: door inner panel, sidebody, longitudinal B: roof, tailgate ,trunklid outer panel Laser robot
4. 6 Blind Rivet
Aston_Martin_Demo_DB11
① Manual application , low efficiency, not ok for modern production手动连接，低效率，不适合大批量现代化操作 ② Pre-hole needed for blind rivet 需要通孔 ③ High cost 高成本
Cadillac CT6 Ford F150
Range Rover
Tesla Model X
Tesla Model S
A.M DB11
3. General Joining Aluminium Body SPR (Self Pierced Rivet) Bonding (structural adhesive applying) FDS(Flow Drill Screw) CMT(Cold Metal Transfer) Spot weld Blind Rivet Laser welding Hemming Bolt/Clinch
Steel
67
4.2 95.8 0
64.5 32.5 3
51Βιβλιοθήκη Baidu48 1
Semitubular Rivet (SPR)
Aluminium 26 others 7
Strcutural adhesive
General connections
Car name
Spot weld (steel) (Al)
FDS
unacceptable
4. 1 SPR (Self Pierced Rivet) Defect check
4. 2 Bonding
① ② ③ ④
Indispensable for Aluminium body: safety, durability, stiffness铝车身必不可少：安全，耐久，刚度 Optional for steel body: lightweight, durability, safety 钢车身也可用：轻量化，耐久，安全 Solution for non-weldable area：焊枪不可达部位用 Manual or automatic applying：人工或者自动涂胶
Structural Adhesive Bonding
4. 3 FDS(Flow drill screw)
① ② ③ ④
One side connection for pre-connection 单面连接 Pre-hole needed when total thickness is not feasible 厚度太厚时候需要过孔 3 layers connection is not recommended 不推荐三层连接 Applying direction: thin thick panel 连接方向从薄到厚
① Widely used on steel body ② High mechanical strength
4. 8 Clinch
Clinch Nut
Clinch Stud
Clinch Sleeve
Benchmark
Percentage use of Steel and Aluminium
Element(%) BMW 7 F150 Benz S-class Jaguar XF
4. Brief introduction for different types of joining
1. Why Aluminum body is gaining its popularity?
EU
China: 2016:6.7L/100km 2020:5.0L/100km
2.1 What vehicles use Aluminum material for body? 2013 Range Rover – 1st all aluminum SUV 2013 Dodge RAM – aluminum hood 2013 Tesla Model S – all aluminum BIW 2014 Cherolet Silverado – aluminum hood 2015 Ford F150 – 1st all aluminum BIW(chassis cab) 2016 Cadillac CT6 – Steel&Aluminum BIW 2016 Tesla Model X – all aluminum BIW 2016 Aston Martin DB11 – all aluminum BIW