Technical Paper
A Manufacturing Performance Comparison of RSW and RFSSW Using a Digital Twin
2024-04-09
2024-01-2053
The design of lightweight vehicle structure has become a common method for automotive manufacturers to increase fuel efficiency and decrease carbon emission of their products. By using aluminum instead of steel, manufacturers can reduce the weight of a vehicle while still maintaining the required strength and stiffness. Body panels are an area in which automotive designers are using aluminum to lightweight their vehicles. Resistance Spot Welding (RSW) is used extensively to join steel body panels but presents challenges for aluminum. When compared to steel, RSW of aluminum requires frequent electrode cleaning, higher energy usage, and more controlled welding parameters, which has driven up the cost of manufacturing. Due to the increased cost associated with RSW of aluminum, Refill Friction Stir Spot Welding (RFSSW) is being considered as an alternative to RSW for joining aluminum body panels.