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This paper describes the development of joint design approach for aluminum space frame. The space frame consists of thin-walled closed extrusions joined by welding. A welded joint cannot be treated by the rigid joint assumption for the effect of the weld line. The continuous fillet parts are modelled as interface elements using detailed finite element model. The study presents the equivalent effective Young's modulus and the effective zone with equivalent modulus. The structural joint stiffnesses of several pillars are calculated by the present joint design method and examined by stiffness test. The effects of fillet size, wall thickness and pillar geometry are considered. The results provide a useful and general method to predict the stiffness of joints with various configurations, and practical guidelines to analyze the stiffness of aluminum space frame.

Aluminum for an automotive has greater potential benefits than steel, from the viewpoint of conservation of natural resources and the market for recycling. Aluminum has a good energy absorption property as well as has contributed to weight-reduction and recycling. These advantages have been utilized on electric vehicles that consist of aluminum space frames and other aluminum components. From the viewpoint of the crashworthiness, the side members of an aluminum space frame play an important role in frontal crash. Occupant analyses are accomplished for the aluminum space frame vehicle and the results are verified by comparison with real experiment. The experiment is a barrier test that is carried out by frontal impact. With the model validated by test results, modifications have been made to improve the crashworthiness and to minimize the injury of passenger by modifying the side members of die aluminum space frame.