Efforts to reduce vehicle weight and improve crash performance have resulted in increased application of advanced high strength steels (AHSS) and a recent focus on the weldability of these alloys. Resistance spot welding (RSW) is the primary sheet metal welding process in the manufacture of automotive assemblies. Integration of AHSS into the automotive architecture has brought renewed challenges for achieving acceptable welds. The varying alloying content and processing techniques has further complicated this initiative. The current study examines resistance spot welding of high strength and advance high strength steels including high strength low alloy (HSLA), dual phase (DP) and a ferritic-bainitic steel (590R). The mechanical properties and microstructure of these RSW welded steel alloys are detailed. Furthermore a relationship between chemistries and hardness is produced. The effect of strain rate on the joint strength and failure mode is also an important consideration in the design of welded structures. Current literature, however, does not explain the effects of weld microstructure and there are no comprehensive comparisons of steels. This work details the relationship between the joint microstructure and impact performance of spot welded AHSS. Quasi-static and impact tests were conducted using a universal tensile tester and an instrumented drop tower, respectively. Results for elongation, failure load and energy absorption for each material are presented. Failure modes are detailed by observing weld fracture surfaces. In addition, cross-sections of partially fractured weldments were examined to detail fracture paths during static loading. Correlations between the fracture path and mechanical properties are developed using observed microstructures in the fusion zone and heat-affected-zone. Friction stir spot welding (FSSW) has proven to be a potential candidate for spot welding AHSS. A comparative study of RSW and FSSW on spot welding AHSS has also been completed. The objective of this work is to compare the microstructure and mechanical properties of Zn-coated DP600 AHSS (1.2mm thick) spot welds conducted using both processes. This was accomplished by examining the metallurgical cross-sections and local hardnesses of various spot weld regions. High speed data acquisition was also used to monitor process parameters and attain energy outputs for each process.

Efforts to reduce vehicle weight and improve crash performance have resulted in increased application of advanced high strength steels (AHSS) and a recent focus on the weldability of these alloys. Resistance spot welding (RSW) is the primary sheet metal welding process in the manufacture of automotive assemblies. Integration of AHSS into the automotive architecture has brought renewed challenges for achieving acceptable welds. The varying alloying content and processing techniques has further complicated this initiative. The current study examines resistance spot welding of high strength and advance high strength steels including high strength low alloy (HSLA), dual phase (DP) and a ferritic-bainitic steel (590R). The mechanical properties and microstructure of these RSW welded steel alloys are detailed. Furthermore a relationship between chemistries and hardness is produced. The effect of strain rate on the joint strength and failure mode is also an important consideration in the design of welded structures. Current literature, however, does not explain the effects of weld microstructure and there are no comprehensive comparisons of steels. This work details the relationship between the joint microstructure and impact performance of spot welded AHSS. Quasi-static and impact tests were conducted using a universal tensile tester and an instrumented drop tower, respectively. Results for elongation, failure load and energy absorption for each material are presented. Failure modes are detailed by observing weld fracture surfaces. In addition, cross-sections of partially fractured weldments were examined to detail fracture paths during static loading. Correlations between the fracture path and mechanical properties are developed using observed microstructures in the fusion zone and heat-affected-zone. Friction stir spot welding (FSSW) has proven to be a potential candidate for spot welding AHSS. A comparative study of RSW and FSSW on spot welding AHSS has also been completed. The objective of this work is to compare the microstructure and mechanical properties of Zn-coated DP600 AHSS (1.2mm thick) spot welds conducted using both processes. This was accomplished by examining the metallurgical cross-sections and local hardnesses of various spot weld regions. High speed data acquisition was also used to monitor process parameters and attain energy outputs for each process.

The research in this report seeks to develop a highly flexible geometry station for joining futureBody-in-White (BiW) assemblies. The goal is to eliminate the need for a complete reconstructionof a production line during integration of new car bodies in a contemporary production.Today's BiW production is performed in sequential lines, where joining equipment is arranged ina specific order for each model geometry. An increasing model portfolio forces manufacturers todevelop production systems that allow an integration of new models. Electrified alternatives ofexisting models are now developed and put into production. These models have similarappearance as conventional models, but with a completely different principle of driveline due tothe propulsion. This means that new interfaces and platforms have to be developed and mustnow be integrated into a current production. Today's production lines are not prepared forcoming changes, and current stations can only handle a limited number of variants. Integration ofnew geometries into a contemporary production line is not sufficiently efficient from aproduction perspective. The goal of the future is to make such an integration possible.Initially, current and future production scenarios were studied. Based on this, four types ofproduction scenarios, which a highly flexible geometry station can be integrated into, were set up.An integration can take place in different ways depending on how a highly flexible geometrystation is compounded, therefore, different cases were created and compared in a case study.Internal and external benchmarking of production systems were made to compare the availablesolutions for increasing stations flexibility in a BiW production.As reference for the project, a concept for a highly flexible geometry station has been developedand is therefore described initially before an additional depth has been realized. The furtherconceptualization of a highly flexible geometry in this report is presented in the form of amorphological composition of technologies that can increase a station's flexibility, as well asvisualization of a station principles through layouts and cycle time charts. The result of theanalysis generated several concepts that hold different degrees of capacity, footprint andflexibility. The focus was to achieve a high level of flexibility for integration of new models, withnew geometries, in a current production. The conclusion was that the highly flexible geometrystation can, in a contemporary production, produce independently in low volumes. Alternatively,produce higher volumes when it is integrated as a complement in a novel, not yet implemented,production concept. / Forskningen i denna rapport syftar till att utveckla en högflexibel geometristation för fogning avkommande Body-in-White-karosser (BiW). Målet är att eliminera behovet av en fullständigrekonstruktion av en produktionslinje under integrering av nya bilar i en samtida produktion.Dagens BiW-produktion sker i sekventiella liner, där fogningsutrustning är arrangerad i enspecifik ordning för respektive modellgeometri. Ett ökande antal modellalternativ drivertillverkare till att utveckla produktionskoncept som möjliggör integration av nya modeller.Elektrificerande alternativ till befintliga modeller utvecklas kontinuerligt. Dessa modeller ärutseendemässigt lika de konventionella modellerna, men med en helt annan princip för drivlina.Det innebär att nya gränssnitt och plattformar har tagits fram och måste nu integreras i ennuvarande produktion. Dagens produktionslinjer är inte förberedda för kommande förändringaroch nuvarande geometristationer kan endast hantera ett begränsat antal karosstyper. Integrationav nya karosstyper i en befintlig produktionslinje är inte är tillräckligt effektivt ur ettproduktionsperspektiv. Framtidens mål är att göra en sådan integration möjlig.Inledningsvis studerades nuvarande- och kommande produktionsscenarion. Utifrån det beskrevsfyra produktionstyper, vilket en högflexibel geometristation kan komma att integreras i. Enintegration kan ske på olika vis beroende på hur en högflexibel geometristation tillämpas, därförjämfördes olika fall av det i en Case-studie. En intern och extern benchmarking avproduktionssystem gjordes för att jämföra de lösningar som finns för att öka flexibiliteten i enBiW-produktion.Som referensunderlag till projektet har ett koncept för en högflexibel geometristation tagits framoch är beskrivet inledningsvis innan en ytterligare fördjupning har realiserats.Konceptualiseringen av en högflexibel geometristation i denna rapport är presenterad i form aven morfologisk sammansättning av teknologier som kan öka en stations flexibilitet, samtvisualisering av en principiell station genom layouter och cykeltidsdiagram. Resultatet av analysengenererade flera koncept som innehar olika grad av kapacitet, fabriksyta och flexibilitet. Fokus varatt uppnå en hög flexibilitetsnivå för integration av nya modeller, med nya geometrier, i ennuvarande produktion. Slutsatsen var att den högflexibla geometristationen kan, i en nutidaproduktion, producera självständigt i låga volymer. Alternativt producera högre volymer då denintegreras som ett komplement till ett ännu inte implementerat nytt produktionskoncept. / Die Forschung in diesem Bericht zielt darauf ab, eine hochflexible Geometrie-Station für das Fügen zukünftiger Rohbau-Baugruppen zu entwickeln. Das Ziel ist es, die Notwendigkeit einer vollständigen Rekonstruktion einer Produktionslinie während der Integration neuer Karosserien in einer modernen Produktion zu beseitigen. Die heutige Rohbau Produktion wird in sequenziellen Linien durchgeführt, wobei die einzelnen Fügeverfahren in einer bestimmten Reihenfolge, angepasst an die jeweilige Modellgeometrie, angeordnet sind. Ein zunehmendes Modellportfolio zwingt die Automobilhersteller zur Entwicklung von Produktionssystemen, die eine Integration neuer Modelle ermöglichen. Elektrifizierte Varianten bestehender Fahrzeugmodelle werden nun entwickelt und in Produktion gebracht. Diese Modelle haben ein ähnliches Erscheinungsbild wie herkömmliche Modelle, jedoch mit einem stark veränderten Antriebskonzept. Dies bedeutet, dass neue Schnittstellen und Plattformen entwickelt wurden und nun in eine aktuelle Produktion integriert werden müssen. Heutige Produktionslinien sind nicht auf kommende Änderungen vorbereitet und können nur eine begrenzte Anzahl von Varianten handhaben. Die Integration neuer Geometrien in eine moderne Produktionslinie ist aus Produktionssicht nicht effizient, aber soll in Zukunft das Ziel sein. Zunächst wurden aktuelle und zukünftige Produktionsszenarien untersucht. Darauf aufbauend wurden vier Arten von Produktionsszenarien erarbeitet, in die eine hochflexible Geometriestation integriert werden kann. Je nach Aufbau der Geostation kann eine Integration auf unterschiedliche Art und Weise erfolgen. Daher wurden in einer Fallstudie unterschiedliche Fälle erstellt und verglichen. Ein Benchmarking mit internen und externen Produktionssystemen wurde durchgeführt, um eine größtmöglichste Flexibilität der Stationen in einer Rohbau Produktion zu erzielen. Als Referenz für das Projekt wurde ein Konzept für eine hochflexible Geometriestation entwickelt und im Rahmen der Thesis dokumentiert, bevor eine zusätzliche Tiefe realisiert wurde. Die weitere Konzeptionierung einer hochflexiblen Geometrie-Station wird in Form einer morphologischen Zusammensetzung von Technologien präsentiert. Dieser kann die Flexibilität einer Station erhöhen und zudem die Visualisierung von Stationsprinzipien, beispielsweise durch Layouts oder Zykluszeitdiagramme, fördern. Das Ergebnis der Analyse erzeugte mehrere vi Konzepte, die unterschiedliche Grade an Kapazität, Grundfläche und Flexibilität beinhalteten. Der Fokus lag auf einer hohen Flexibilität bei der Integration neuer Modelle mit neuen Geometrien in einer aktuellen Produktion. Die Schlussfolgerung war, dass die hochflexible Geometriestation in einer zeitgemäßen Produktion in kleinen Stückzahlen produzieren kann. Alternativ ist die Geo-Station auch als Bestandteil eines noch umzusetzenden Produktionskonzepts integrierbar.

Friction bit joining (FBJ) is a new solid-state spot joining technology developed in cooperation between Brigham Young University of Provo Utah, and MegaStir Technologies of West Bountiful Utah. Although capable of joining several different material combinations, this research focuses on the application of FBJ to joining 5754 aluminum to DP 980 steel, two alloys commonly used in automotive applications. The thicknesses of the materials used were 0.070 inches (1.78 mm) and 0.065 inches (1.65 mm), respectively. The FBJ process employs a consumable 4140 steel bit and is carried out on a purpose built research machine. In the first stage of the weld cycle the bit is used to drill through the aluminum top sheet to be joined. After this, spindle speed is increased so that the bit tip effectively forms a friction weld to the steel bottom sheet. Momentary stoppage of the spindle facilitates weld cooling before the spindle is restarted, shearing the bit tip from the bit shank, and retracted. Incorporated into the bit tip geometry is a flange that securely holds the aluminum in place after joint formation is complete. This research consists of several developmental steps since the technology only recently began to be formally studied. Initial joint strengths observed in lapshear tensile testing averaged only 978.5 pounds (4.35 kN), with a relatively high standard deviation for the data set. Final lapshear tensile test results were improved to an average of 1421.8 pounds (6.32 kN), with a significantly lower, and acceptable, standard deviation for the data set. Similar improvements were realized during the development work in cross tension tensile test results, as average strengths increased from 255.8 pounds (1.14 kN) to 566.3 pounds (2.52 kN). Improvements were also observed in the standard deviation values of cross tension data sets from initial evaluation to the final data set presented in this work.