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Challenge to Welding and Joining Technology for Applying Multi-material in Electric Vehicle Production



Author(s)

Tomoyuki Ueyama¹, Shinichi Hasegawa¹, Takaaki Miyauchi¹, Testuo Era¹ and Hidetoshi Fujii²

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DOI:10.17265/2161-6213/2022.10-12.001

1. DAIHEN (OTC) Corporation, Kobe 658-0033, Japan
2. Joining and Welding Research Institute Osaka University, Ibaraki 567-0047, Japan

Advanced high strength steel, aluminum alloy and plastic materials are used in the right places for the purpose of reducing the weight of EV (electric vehicle) bodies and in-vehicle parts, and multi-material structures are advancing. Therefore, it is difficult to handle the welding and joining processes of automobile structures by the conventional arc welding and resistance spot welding, which have been applied to steel joining, and various joining processes are being applied depending on the material. Under above mentioned background, the authors have developed some unique joining processes for multi-materials that are used in the right place. This paper introduces the dissimilar metal joining between the galvanized steel and aluminum alloy by laser arc hybrid process, the metal/thermoplastic dissimilar material joining using laser process and the solid-state resistance spot joining process of advanced high strength steel for EV body structural parts. Moreover, the authors describe the high-speed plasma jet GTA (Gas Tungusten Arc) welding process of copper applied to electrical components such as motors.

Arc welding, laser arc hybrid, dissimilar joining, spot joining, electric vehicle.