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The advent of various structural optimization methods has made the process of deriving efficient lightweight designs for complex structures under multiple load conditions far more attainable than ever before. Three of these methods, namely sizing, topology and topometry optimization have been used extensively in the structural optimization of body-in-white structures. While all these techniques have their unique advantages, they provide different solutions to the posed problem. In this paper, we examine how best these optimization techniques can be used to derive a more efficient design within a linear domain, through a case study. Depending on the starting point of the design, all three techniques can play a vital role in making design decisions.

Joining methods for spaceframe architectures using extruded structural elements are getting popular. At present, the development of lightweight vehicles, in particular aluminum intensive vehicles, requires substantial development of manufacturing processes for the joining and assembling. Joining methods, such as electric arc resistance, and laser beam fusion welding together with nonfusion ultrasonic welding rise as possible alternatives for high volume joining of aluminum. In this study, metal inert gas (MIG) welding was used to join heat treatable extruded 6063 T6 aluminum alloys. The purpose of this study was to find optimum MIG welding parameters for joining 6063-T6 extruded aluminum. Also, the MIG welding equipment used in this study is OTC TP 350 DF weld power supply and DR-4000 robotic system. The welding process factors considered were power input (voltage, current, and torch speed), pulse frequency, gas flow rate, torch angle and arc intensity.

Aluminum alloys are becoming more lucrative in automotive structural applications. In recent automotive history, 5xxx and 6xxx aluminum alloys are being used in various structural applications. Various joining methods are also popular for joining 5xxx, and 6xxx series alloys. In this study, gas metal are welding (GMAW) also referred as metal inert gas (MIG) welding is used to join a non-heat-treatable alloy. The objective of this paper is to develop optimum weld process factors for double lap joint configuration for non-heat-treatable 5754 aluminum alloy. Ultimately, these optimum weld factor settings (also referred as weld schedules) will be used in the plant level for joining 5754 alloy materials. Also, the MIG welding equipment used in this study is OTC TP 350 DF weld power supply and DR-4000 robotic system. The weld factors selected for this study to understand the influence on lap shear load failure are power input (torch speed, voltage, current, wire feed), and gas flow rate.