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 New federal fuel economy requirements are pushing
automobile manufacturers to use lighter materials, including aluminum.
Assembling aluminum body parts to steel frames has typically depended on
adhesives and rivets. However, both methods have limitations due to cost and how
well the joints hold. Automakers have developed three new welding methods
for joining aluminum to other metals: stir, laser, and resistance spot welding.
Both stir and spot welding use modified heads that break down the oxide layer of
the aluminum, enabling stronger bonds between aluminum, steel, and other metal
alloys. All three methods can join parts at production speeds at comparable or
lower cost than rivet joints.
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Re: Automakers Perfect New Aluminum Welding Systems
