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Development of Steel and Aluminum Continuous Welding Technology Using FSW and Application to Subframes

Article of Honda R&D Technical Review Vol.25 No.1

Summary

Continuous welding technology that uses Friction Stir Welding and has a welding strength equal to or above that of MIG welding was developed to weld together steel parts and aluminum parts, and at the same time technology was also developed to rustproof areas where dissimilar metals are welded. In order to apply this welding technology to mass production, an original welding system using an industrial articulated robot was developed, and application was realized with an efficiency and investment equivalent to that of conventional MIG welding. In addition, an inspection system using a highly sensitive infrared camera and laser beam was also developed as a non-destructive in-line system to assure joint strength. This technology was applied to the front subframe, which is a structural component of mass-production vehicles. As a result, compared to the previous model, the weight was reduced by 25%, the rigidity of the suspension mounting point was increased by 20%, the vehicle’s dynamic performance was enhanced, and electrical power consumption during the welding process was reduced by 50%.

Reference

(1) Kobayashi, T., Sayama, M., Yahaba, T., Kato, T.: Development of Friction Stir Welding Technology for Subframe for Fuel Cell System, Honda R&D Technical Review, Vol. 21, No. 1, p. 49-57
(2) Shimoda, Y., Tsubaki, M., Yasui, T., Fukumoto, M.: Effect of Material Flow on Formation of Weld Interface between Aluminum and Steel by Friction Stirring, Japan Welding Society, No. 89, p. 142-143, (2011)
(3) Ogura, T., Saito, Y., Nishida, T., Nishida, H., Yoshida, T., Ohmichi, N., Fujimoto, M., Hirose, A.: Interfacial microstructure and its mechanical property in friction stir welded A3003/SUS304 dissimilar lap joint using WC tool, Japan Welding Society, No. 89, p. 120-121, (2011)
(4) Tokisue, H., Shinoda, T., Kumagai, M.: FSW no jisshi rei, FSW (Masatsu kakuhan setsugou) no kiso to oyo, Nikkan Kogyo Shinbunsya, p. 105-127, (2005) (in Japanese)
(5) Japan Friction Welding Association: Friction Welding Technology, Nikkan Kogyo Shinbunsya, p. 191-193, (2006) (in Japanese)
(6) Industrial Robot: An international Journal, Volume 31, Number 1, p. 55-63 (2004)
(7) Industrial Robot: An international Journal, Volume 37, Number 1, p. 36-50 (2010)

Author (organization or company)

Tetsuya MIYAHARA(Automobile R&D Center)、Mitsuru SAYAMA(Automobile R&D Center)、Takanori YAHABA(Honda Motor Co., Ltd.)、Shousuke OHHAMA(Automobile R&D Center)、Tsunehisa HATA(Automobile R&D Center)、Tsutomu KOBAYASHI(Automobile R&D Center)

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