Joining technologies of and aluminium spaceframes in automotive in kfueit rahim yar khan Best Regards, Tanvir Malik Mechanical Engineers. Khawaja Fareed University of Engineering and Information Technology (KFUEIT), Abhu Dhabi Road, Rahim Yar Khan, Punjab, Pakistan.

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DEPARTMENT OF
MECHANICAL
ENGINEERING
Presented To: Dr. Muhammad Umer Farooq
Presented By:
Tanvir Malik
Abdul-Rehman
Waqar Ahmed
Talha Ali
Vijay Kumar
ME171012
ME171014
ME171031
ME171056
ME171057

3. JOINING TECHNOLOGIES OF AND
ALUMINIUM SPACEFRAMES IN AUTOMOTIVE 3

4. AIM OF PRESENTATION4
To highlight the Joining Technologies of
Aluminium Spaceframes.
 Conclude the results and identify the
possible Solutions

5. SEQUENCE OF PRESENTATION
Introduction
Joining Techniques of Aluminum Spaceframe
Conclusions
Quires and Answer
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3
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6. INTRODUCTION TO JOINING TECHNOLOGIES
AND IMPORTANCE
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 Spaceframes of in Auto motives
 Replacement of Materials
 Body Weight in Vehicles

7. JOINING TECHNOLOGIES MANUFACTURING
POCESSES
This section reviews joining technologies that are currently used in
manufacturing of various products
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Resistance Welding Laser Welding Ultrasonic Welding

8. RESISTANCE WELDING8
Resistance welding relies on
the electrical resistance at
the metal interface to cause
a localized heating and
fusion of materials.
Aluminum and copper are difficult to be resistance
welded due to their high thermal and electrical
conductivities.
Wide application in the
automotive, electronics, and
heavy industries. used in small
sized and cylindrical battery cell
manufacturing because of its
advantages.

9. LASER WELDING9
Laser welding is a non-contact process
that joins multiple pieces of metal
through the laser. rapidly heats the
material, typically in milliseconds
Very high precision of welding, Less
thermal input less distortion also laser
welding is high speed operation.
Use of laser weld is to weld
battery electrolyte
containers, inter
connectors, and bus-
components.

10. ULTRASONIC WELDING10
A process which uses high
frequency usually at
20kHz or above,
oscillating shear is
produce by ultrasonic
energy to create solid state
bond between two sheets
that is clamped under
pressure.
This type of welding
can be used to join
thin foils and
different types of
metals also to
dissimilar materials.
Restricted to lap
joints also make
large weld
indentation
No filler metals
Challenging to high
strength and high
hardness materials.

11. JOINING TECHNIQUES OF ALUMINUM
SPACEFRAME
It is old welding technique and frequency range is 50 HZ to 60
HZ with AC supply use.
From spot welding many problem solved like as aluminum
welding.
Intensive process for this reason it is confined in spaceframe
fabrication process.
Mostly used in automotive industry.
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Spot Welding

12. JOINING TECHNIQUES OF ALUMINUM
SPACEFRAME
 Arc welding is more famous due to best technology. In arc welding use
TIG,MIG,MMA welding.
 From arc welding aluminum welding is more difficult.
 In arc welding cracking is done. To avoid carking use filler with silicone
content.
 In arc welding distortion occurs due to lot of heat input.
 In arc welding eye disease occurs.
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Arc Welding

13. FRICTION STIR WELDING13
The heat generated
by friction that
causes the material
to plastic is
producing the
weld.
Simple tool which rotates
along a joint line to
produce solid state welds
by using a friction steel
welding a relatively new
process develop by Twi.

14. ADVANTAGES OF FRICTION STIR WELDING14
There is no
requirement to
clean the metal
surface it can be
applied to various
types of joints like
lap joints, butt
joints
Friction stir
welding is a green
technology it does
not produce any
health hazards
materials which
may leads to
destruction of
environment or
people
Good mechanical
properties of
welded joints.

15. LIMITATIONS OF FRICTION STIR WELDING15
An exit hole is
produced when
tool is withdrawn
form the
workpiece.
Many times this
welding process is
slower than many
other processes
Initial cost of FSW
machine is too
high

16. OTHER DEVELOPING TECHNIQUES ?
Diffusion bonding
 Cold
− High Pressure
− High Strain Rate
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High Temperature
−Low Pressure.
−Lower Strain Rate
(~500˚C Temperature)
Advantages:
 Simple starting blank forms.
 High material Utilization.
 Processing times are insensitive to size, complexity of
structural form or number of components manufactured
in one operation

17. FINE PLASMAARC
Highly concentrated and controllable source of heat energy
Electric arc is produce from electrodes within touch Strips
Heat is produced when the arc ionizes the gas
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Technologies to stabilize the plasma jet
 Gas is swirled through the inner chamber of the torch at a high velocity to form a
vortex.
 The plasma which is electrically conductive is then magnetically focused.

18. CONCLUSION18
The industries of automotive has developed the most interest
for manufacturing of spaceframe.
There are some important technical problems in tackle to weld
aluminium.
Friction stir welding is not capable to weld different profiles
and crooked surfaces.
The industry of automotive offers that most of economic and
technical problems defined will immediately be control.

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•Thank You