This work compares three aluminium sheet joining processes to determine their capability, efficiency and cost for mass production applications in automotive structures and closures. The joining processes investigated are Resistance Spot Welding (RSW), SelfPierce Riveting (SPR) and Spot Friction Joining (SFJ). Quantitative comparisons have been made on the basis of tensile strength (shear and peel), process time, equipment price and running cost.RSW is the most commonly employed joining method for steel sheet in the automotive industry. Its principle benefits are high speed and low cost operation, plus the ability to weld a wide range of joint configurations with the same gun. The main process limitations for aluminium are weld consistency and electrode-life, though recent work has shown that both of these can be largely overcome with regular electrode polishing [1,2]
The present paper is concerned with hybrid laser-arc welding processes. Previous work is reviewed, and attention is then focused on plasma augmented laser welding. Features, application parameters, and mechanisms of the process are discussed, followed by a summary of the research and development work undertaken by the present authors, concentrating on application areas where the process can offer distinct advantages, such as tailor welded blanks, lap welding of coated steels, welding using additional filler material, and high speed welding of thin sheet metals.
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