Joining technologies in automotive industry. Some examples of Body In White joining methods
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1 Joining technologies in automotive industry Some examples of Body In White joining methods
2 Overview Used Joining Technologies in the Automotive field (BiW) Welding Gluing Sheetmetal Screwing Riveting Clinching Hybrids 2 Valmet Automotive 3/7/2016
3 Welding Most common welding processes in Automotive BiW Resistance Welding Spot Welding Deltaspot Projection Welding Seam Welding Stud Welding Laser Arc Welding MIG / MAG TIG CMT Laser Welding Laser Welding Remote / Scanner Hardfacing Laserhybrid Electron Beam Welding Weldinggun higher tolerances due to self clamping moderate tolerances due to gap filling Requires small tolerances, expensive clamping Used by VA Partly used by VA Usable for Aluminium 3 Valmet Automotive 3/7/2016
4 Welding Resistance Welding Aluminium Spot Welding - Deltaspot (Fronius) - Influencing the resistance of the material by adding a driven metal strip. The strip is endless and is driven after every new spot welded. Advantages - No aloycreation of welding material on the welding caps - Can influence the position of the welding lense and shape, when different material strenghts and difficult workpiece geometries are used - Endless metal strip, has not to be changed during production time (except 3-Shift) - Can influence parameters positively Disadvantages - Higher Invest compared to standart SW tooling 4 Valmet Automotive 3/7/2016 Deltaspot Welding Gun 3-Sheetmetal junction of AlMg3 with 17kA, 700ms, 4kN (0.3mm,1.0mm & 2.0mm)
5 Welding Resistance Welding Aluminium Spot Welding - GM (Hirotec) - Multi-ring domed electrodes - CSS weld schedules - Aluminum specific equipment set Advantages - Almost normal type of welding equipments can be used - Allow different material strenghts and smal workpiece geometry variation. - Standardized type of process Disadvantages - Higher Invest compared to standart SW tooling - Needs automated electrode cap dressing and electode cap changer - Higher weight of welding gun 5 Valmet Automotive 3/7/2016
6 Welding Resistance Welding Aluminium Spot Welding - GM (Hirotec) - Multi-ring domed electrodes - CSS weld schedules - Aluminum specific equipment set Multi-Ring Domed Electrodes - Standard weld cap dressed with custom cutting blade - Multi-Ring texture strains the part surface to reduce contact resistance - Domed cap improves robustness to nonidel welding conditions (i.e. off angle, gaps between parts) 6 Valmet Automotive 3/7/2016
7 Welding Resistance Welding Aluminium Spot Welding - GM (Hirotec) Cont. - Multi-ring domed electrodes - CSS weld schedules - Aluminum specific equipment set CSS Weld Schedules - Conditioning Remove effects of part variance Seats caps without melting - Shaping Weld nugget initiation at center of welding location - Sising Nugget growth at lower current levels Improve heat affected zone 7 Valmet Automotive 3/7/2016
8 Welding Resistance Welding Aluminium Spot Welding - GM (Hirotec) Cont. - Multi-ring domed electrodes - CSS weld schedules - Aluminum specific equipment set Equipment Set - MFDC weld control 1200 Amp WTC - Larger weld transformers Weld current to 55 kamps - Increased gun stiffness Weld forces to 5.4 kn - Automatic tip dressing welds/dress - Automatic cap changing dresses/cap 8 Valmet Automotive 3/7/2016
9 Welding Resistance Welding Projection Welding - Influencing the resistance of the material by chaniging geometry. Advantages - Can reach corners and other difficult geometries through adaption of welding geometry - Can influence welding parameters - Low waste on welding caps - Multiple weldings at once - Creation of mixted microstructure possible - Different material strenghts prossible Disadvantages - Additional process needed (forming geometry) - Needs special equipment = higher invest compared to standart SP 9 Valmet Automotive 3/7/2016 Projection Melted material circulates with ca. 20m/s in the magentic field
10 Welding Resistance Welding Seam Welding - Continous resistance welding through replacing electrodes with copper wheels. Advantages - Continous seams, saving gluing process - Easy to paint - Good optical aperience - Can create spots and continous seams Disadvantages - Aloy creation on the wheels, when using Aluminium or zinkplated materials - No easy reaplacement of wheels possible - Complex process, hard to stabilze - More sensors needed trough moving along a defined path - no small curves possible 10 Valmet Automotive 3/7/2016 Seam on a tube
11 Welding Arc Welding TIG Welding (Tungsten Inert Gas) - Creates an arc between non consumable tungsten electrode and work piece. Ignition through short circuit or high frequency voltage. Advantages - Very good optical seams - Good control of process - Mainly used for non ferro metals (Aluminium, Stainless Steel, Copper, Magnesium) - Requires accessabilty only from one side Disadvantages - Very slow compared to other arc welding processes - Requires skilled labour - Not easy to automate with e.g. Industrial robots 11 Valmet Automotive 3/7/2016
12 Welding Laser Welding Standard Laser Welding / Soldering - Focussed laser photones heat up the workpiece and, if used, suplementary material. Advantages - Very fast welding speed (>4,5m/min) - Same Hardware used for welding and brazing - Good looking seams - Top hat optics get energy density more homogenious - Workpiece only heats up at the seam - No strong deformation of workpiece - Requires accessabilty only from one side Disadvantages - Very high invest, operational costs & maintenance - Requires high precision from workpiece and environment - High effort for safety (Lasercabins, glasses) 12 Valmet Automotive 3/7/2016 Laser welding Laser brazing of rear door (Audi A3)
13 Welding Laser Welding Laser Soldering Valmet (Scansonic) System description - Power source Trumpf TruDisk Welding optics Scansonic ALO3 - Wire feeding Binzel - Welding wire Fontargen A202 M EC 1,0 mm (CuSi3Mn) 13 Valmet Automotive 3/7/2016
14 Welding LaserWelding Laser Soldering Valmet (Scansonic) 14 Valmet Automotive 3/7/2016
15 Welding Laser Welding Remote / Scanner Welding (Laser) - Laserbeam is positioned with fast mirriors to the workpiece. Advantages - Very fast positioning and welding speed - Small seams possible (<0.5mm) - Also used for lasercutting - Can be used for gap filling by rotation circles / ellipses - High distance from workpiece - Can reach difficult areas - Workpiece only heats up at the seam - No strong deformation of workpiece - Requires accessabilty only from one side Disadvantages - Very high invest, operational costs & maintenance - Requires high precision from workpiece and environment - High effort for safety (Lasercabins, glasses) 15 Valmet Automotive 3/7/2016 Remote welding door Up to 200 welds / minute
16 Welding Laser Welding Laser Scanner Welding Valmet (RobScan) System description - Power source, Trumpf TruDisk Welding optics, Trumph PFO - Welding on the fly - operation - Machine vision for quality inspection, Hema electronics GmbH VISIR (Daimler patented) Robscan Weld Seam Characteristic - Robscan welds consists of 4 operations per seam Dimpling (1) Deep penetration welding (2) Reheating of the seam for heat conduction measurement Final Heat conduction welding (3) Vaporization channel Deep penetration weld (2) Heat conduction weld (3) Dimple (1) Metal Sheet 16 Valmet Automotive 3/7/2016
17 Welding Laser Welding Laser Scanner Welding Valmet (RobScan) Dimples Welding finished 17 Valmet Automotive 3/7/2016
18 Welding Laser Welding Laser Scanner Welding Valmet (RobScan) 18 Valmet Automotive 3/7/2016
19 Welding Hybrid Welding Laserwelding Gun (IPG Photon) - Combination of concept advantages of spotwelding with laser technology. Advantages - Very fast positioning and welding speed (80mm/s) - Speed andvantage over spot welding up to 50% - Small seams possible (<0.5mm) - Workpiece only heats up at the seam - No strong deformation of workpiece - No high requirement in accuracy of workpiece - No Lasercabin needed - Can be used on Aluminium Disadvantages - Requires accessabilty from both sides - Combination with glue is questionable - high invest, operational costs & maintenance - Needs flat workpiece geometry 19 Valmet Automotive 3/7/2016 Classical SW 10,5 sec Laserweldinggun 5,0 sec
20 Gluing General Gluing information Advantages - Nearly all kind of materials can be combined - Big areas are easier to cover than with other joining technologies - Good damping properties - Lightweight - No microstructure damage of material - Sealing - Cold connection needs usually curing Disadvantages - Preparation processes needed - Not as resistend towards temperature - Aging - Not testable (destructionfree) 20 Valmet Automotive 3/7/2016
21 Gluing Application in BIW 21 Valmet Automotive 3/7/2016
22 Gluing Application in BIW 22 Valmet Automotive 3/7/2016
23 Gluing Application in BIW 23 Valmet Automotive 3/7/2016
24 Screwing Sheetmetal screws FDS Flow Drill Screw - The friction heat, generated through high force ( N) and turn speeds ( rpm), melts a hole. After reduction of the rpms a will then form a screw thread which is thicker than the original material Advantages - Thicker screw thread than with normal sheet metal screws - No chipping - Fast process - Accessabilty only from one side - Can be loosend afterwards Disadvantages - Screw can be tightend again - can t be used on visible surfaces 24 Valmet Automotive 3/7/2016
25 Tubular Rivet Bolt Rivet Locking Ring Rivet Hollow Rivet Stud Rivet Hollow rivet with rivet caps Pierce Rivet Hollow Punch Rivet Riveting Piercing & Non Piercing - Riveting using friction and clamping forces to connect workpieces. Piercing rivets are used mainly in sheetmetal production as BiW Advantages - Can combine nearly any material combinations - High forces through frictional and clamping connection - Cold connection - Can be easily combined with glue Disadvantages - Slow process compared to welding - Requires accessibility from both sides - Contact corrosion between rivet and material possible 25 Valmet Automotive 3/7/2016 Piercing Riveting Non Piercing Riveting
26 Clinching Point form / Flat form - Assembly parts from sheet metal and formable materials are stacked in the joining position and fixed. A press ram into the die and deformes the parts plastically. Advantages - Cool joining technology - No special treadment of the parts before or after - Better surface than rivets - One side easy to paint Disadvantages - Requires accessabilty from both sides - Slower than spot welding - Contact corrosion possible 26 Valmet Automotive 3/7/2016
27 Hybrid Clinchriveting Fraunhofer IWU & TOX (Tox patented) - Using a rivet as a stamp for clinching, which remains in the connection. The used rivets are piercing or hollow punch rivets without penetrating the workpieces Advantages - Higher resistance of the connection - Better combination with glue (no airgaps) - Better surface quality (no hole) Disadvantages - More complex - Slow process Center TOX Clinchriveting Flow Deep drawing IWU Clinchriveting Anvil replaces the matrix Rivet de-.formation 27 Valmet Automotive 3/7/2016
28 Hybrid Aluminium Weldbrazing In Development - patented by VW - Joining Aluminium and form hardned steel (22MnB5) with a spotwelding method. Creating CMT suplementary material depots on the steel before to perform a welding and brazing process at once. Advantages - Combination of most important actual materials in BiW through a fast and well known process - Nearly no change in production equipment - Can be combined with gluing Disadvantages - Addittional processes needed to create solder depots - Aluminium alloys to welding gun electrodes and needs more cleaning 28 Valmet Automotive 3/7/2016 AlMg3 Depot 22MnB5 Soldered / brazed connection Weakest spot = AlMg3 Structure Spotwelding electrodes Welded connection
29 Hybrid Rivet Welding In Development - patented by VW - Spotwelding a rivet like metal pin to the carrier material and clamping the inner surface material Advantages - Combination of different materials - Ideal for composite and lightweight design - Very good surface on the carrier material - Can be combined with glueing Disadvantages - Addittional processes needed for holes - Addtional parts needed (rivets) - Contact corrision not solved - Needs accessabilty from 2 sides Rivet Carrier material Inner surface Spotwelding electrodes Rivet 29 Valmet Automotive 3/7/2016
30 30 Thank you Valmet Automotive for your attention!
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