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The new Brazilian automotive regulation, INOVAR, states aggressive energy efficiency targets until 2016 to vehicles sold in Brazil. Many engineering solutions shall be done and implemented by Automakers to adequate current and new vehicles to INOVAR requirements. The Body Structure represents about 40% of vehicle mass and it is fundamental portion of energy efficiency study. The biggest body structure engineers challenge is provide mass reduction changes without jeopardize legal requirements and structural vehicle performance such as: Safety, Reparability, Torsional and Bending Stiffness, Durability, etc. Either Automakers or Suppliers manufacturing have an important task supporting Product Engineers on new parts development with different materials, shapes and joining. The contribution of Body Structure mass reduction for Internal Combustion Engines vehicles is not enough to achieve targets because new Program establishes smaller Energy Consumption for lighter vehicles.

Nowadays quality and efficiency in the process is no longer a question of competition among automakers. Another factor that has been highlighted in the automotive industry and has become a strategic is the sustainability. Processes considered “green” can generate value for the company with less environmental impact, and they are seen favorably by both market and customers. The process to be examined is widely used by automakers to manufacture their bodies in white, the resistant spot welding process. Considering that, this process generates a considerable impact in the environment mainly for the generation of gases, some manufacturers in recent years has replaced it by the clinching process, which also performs the union of sheet metal, but for metal forming. The process of spot welding generates dust, fumes and pollutants gases, which will be transported to the external environment somehow.