Master Internship Final Report

Hybrid Joining Technology

Multi material joining for automotive industry 2020
Submitted by
Khandoker Raisul Azad
Registration Number - MAV-1310588003
Academic Supervisor
Lukas Andracher (FH Joanneum)
Company Supervisor
Vallant Rudolf (TU Graz)

In cooperation with

and

Graz, February 2015

Abstract
With the increasing political pressure on the automotive industry to reduce 2 emissions, engineers
are forced to come up with lightweight solutions. The idea of using the right material at the right place
results in multi-material structures with joining technologies of such structures as a critical part.
The main goal of this project work is giving an overview of the present multi-material joining
technologies with respect to their process borders. The different methods are listed in groups which are
represented by process characteristics. This, as the most important objective of the Internship work, is
summarised in the first main part. Within a following part, the mentioned joining methods are evaluated
and compared from multiple points of view with respect to automotive mass production. These views
guide the way to the identification of economically producible, multi-material and well performing
joints for different use cases in automotive engineering. The third part of this project work presents an
exemplary choice of a joining technology for a specific scenario (multi-material-multi-geometry
substructure) in automotive engineering and especially the methodology to do so. Further, the results
of the applied methodology can be used as an identification process of future interesting research
fields/projects with exemplary characteristics like multi-material join ability, joint and joining
characteristics.
This internship work is based on an extensive literature research, whereas none of the mentioned facts
and data came from experiments executed by the author.

Acknowledgement
Throughout my studies I have been supported by many people, I would like to take this page as an
opportunity to express my gratitude for the support during the study and internship. I would like to
express my gratitude first to the almighty. I do appreciate the incessant support of Mr. Vallant Rudolf
(TU Graz) to finish the internship work and guide me towards the goal as well as which help me to
touch the finish line pretty soon. Furthermore, I appreciate the continuous communication of Mr.
Lukas Andracher (FH Joanneum).
A Sincere thanks goes to Mr. Bruno Gotzinger (MAGNA) for giving me the chance to portray my
knowledge to the colossal word of material science.

Khandoker Raisul Azad

Graz, February 2015

Table of Content
1. Introduction-------------------------------------------------------------------------------------------------------- ----------1
2. Lightweight Automotive Design - Overview---------------------------------------------------------------------------6
3. Joining in Multi-Material Design---------------------------------------------------------------------------------------11
3.1 Adhesive Bonding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2 Electromagnetic joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.2.1 Principles of Electromagnetic Pulse Technology. . . . . . . . . . . . . . . . . . . . 20
3.2.2 Electromagnetic Forming . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.3 Electromagnetic Pulse Welding. . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.3 Mechanical Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.1 Roll Bonding/Cladding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.2 Clinching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.3.3 Riveting and Punch Riveting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.3.4 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3.5 Folding/Hemming and Flanging . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.3.6 High-Speed Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.3.7 Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3.8 Thermo-Mechanical Form Joining . . . . . . . . . . . . . . . . . . . . . . 42
3.3.9 Collar Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.4 Thermal Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4.1 Delta Spot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.4.2 Resistance Element Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.4.3 Soldering & Brazing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.4.4 Cold Metal Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.4.5 Cold-Arc & Chop-Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.4.6 Super-Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4.7 Laser Beam Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.4.8 Friction Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.4.9 Magnetically-Impelled Arc Welding . . . . . . . . . . . . . . . . . . . . . . 65
3.4.10 In-Mould Assembly & Compound Casting . . . . . . . . . . . . . . . . . . 68
3.4.11 Thermal Conductivity & Induction Joining . . . . . . . . . . . . . . . . . 76
3.4.12 Laser Transmission Joining . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.13 Ultrasonic Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.5 Hybrid (Multi-Method) Joining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.5.1 3D-Lock Seam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.5.2 Pin Joining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.5.3 Onsert Joining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4. Evaluation and Comparison --------------------------------------------------------------------------------------------87
4.1 Multi-Material Join ability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2 Joint Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.2.1 Static Load Joint Performance . . . . . . . . . . . . . . . . . . . . . . . . 92
4.2.2 Impact Load Joint Performance . . . . . . . . . . . . . . . . . . . . . . . . 97
4.2.3 Dynamic Load Joint Performance . . . . . . . . . . . . . . . . . . . . . . . 98
4.2.4 Joint Performance Summary . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.3 Joining Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.4 Evaluation and Comparison Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
5. Multi-Material and Multi Geometry -------------------------------------------------------------------------------108
5.1 Shock Tower - Casting/Profile Joint . . . . . . . . . . . . . . . . . . . . . . . . . 109
5.2 B-Pillar to Door Sill - Profile/Profile Joint . . . . . . . . . . . . . . . . . . . . . . 110
5.3 Closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.4 Exemplary Joining Method Choice - Quality Function Deployment . . . . . . . . . . . . . . . 112
6. Conclusion -----------------------------------------------------------------------------------------------------------------115
References --------------------------------------------------------------------------------------------------------------------117