Page 38 - Module DMV20173

3.0 SHEET METAL PROCESSES

Example 3.2 Tailor welded sheet metal for automotive applications

An example of the use of tailor-welded sheet metals in automobile bodies is shown in
Figure 3.8. Note that five different pieces are blanked first, which includes cutting by

laser beams. Four of these pieces are 1 mm thick, and one is 0.8 mm thick. These
pieces are laser butt-welded and then stamped into the final shape. In this manner, the
blanks can be tailored for a particular application, not only as to shape and thickness but
also by using different quality sheets—with or without coatings.

Laser-welding techniques are highly developed; as a consequence, weld joints are very
strong and reliable. The growing trend toward welding and forming sheet-metal pieces
makes possible significant flexibility in the product design, structural stiffness, formability,
and crash behavior of an automobile. It also makes possible the use of different

materials in one component, weight savings, and cost reduction in materials, scrap,
equipment, assembly, and labor.

There are increasing applications for this type of production in automotive companies.
The various components shown in Fig. 3.9 utilize the advantages outlined above. For

example, note in Fig.3.9 (b) that the strength and stiffness required for the support of the
shock absorber are achieved by welding a round piece onto the surface of the large
sheet. The sheet thickness in such components is varied (depending on its location and
on its contribution to such characteristics as stiffness and strength) and, thereby, makes

possible significant weight savings without loss of structural strength and stiffness.

BPLK 70 DMV 20173