Fusing aluminum in a multi-material lightweight vehicle is presented via studies on joining dissimilar materials, joining methods, and the performance of the joined materials. The use of aluminum offers a material that embodies properties to meet new standards as the automotive industry continues to pursue improvements in fuel efficiency and emissions. Aluminum’s strength, light weight, and corrosion resistance offers manufacturers a material alternative to steel and an additional material, which has long been known in the industry, to be employed in automotive construction. Topics of technical interest include:

Forming
Galvanic Corrosion
Welding, Fastening, Bonding
Maximizing Weight Benefits


Production of strong, lightweight structures will contribute significantly to automobile manufacturers meeting mandated fuel economy standards, as well as customer preferences for utility, comfort, and safety. Materials selection and application are critical components to the design of lightweight vehicles. Joining technologies and the relationship of the materials that are joined to meet the design and assembly requirements are presented in this work and also frame the foundation for innovative joining methods for the next generation of lightweight vehicles.