GM welding technology for high- volume aluminum structures could benefit heavy trucks, railroad Concentric ings on the domed electrode tip (image at right) are key to the effectiveness of the aluminum resistance-welding technology. GM ‘owns IP around three concepts: the electrode design, the controls for the electrical current, and the technology for dressing the tip intermittently. General Motors is preparing to signif: cantly increase its use of aluminum in ve- hicle body structures with a new twist on an old joining technology: resistance spot ‘welding. The automaker is expanding use of what GMM engineers claim isan indus- tryst aluminum spot-welding process that features a new type of electrode de- veloped and patented by GM R&D. The technology is designed for much higher production rates than are currently ‘employed in automotive aluminum-struc- tures manufacturing, It centers on a new electrode-tip design that will enable Gis Global body shops to spot-veld virtually ‘any combination of aluminum sheet, ex ‘rusions, and castings, according to Blair Carlson, Lab Group Manager, Lightweight, Materials Processing Group, GM R&D. 'No other automaker is spot-welding aluminum body structures to the extent wwe are planning to, and this technology \willallow us to do so at low cost,” he said, By increasing its use of aluminum spot welds per vehicle, GM expects to elim= nate neatly 2 lb (0.9 kg) of selt-piercing 8 SAE OHE novernber8, 2012 rivets from aluminum body assemblies including doors, hoods, and liftgates. Using rivets to join aluminum pieces adds up-front cost, while complicating tend-oflfe recycling efforts. Rivet-aun ‘operating limitations also restrict the joint configurations that can be employed in a structure. GM also aims to commercialize the welding technology, "We've got a good handle on it in our internal production, ‘and we've licensed it to the GM supaliers for upcoming programs,” Carlson told SAE Magazines. "Now we're taking the next step to license it externally for none GM production” which he expects to in clude heavy truck, railroad, and aerospace applications, ‘GM owns a suite of intellectual prop- erty around three concepts: the electrode design, the controls for the electrical cur- ent, and the technology for dressing (cleaning) the electrode tip intermittently Carlson said The resistance-welding technology has been in use on select hood (Cadillac CTS-V) and liftgate (hybrid versions of SAE International SAE International Board of Directors Fronk 0. Kegon chord ising 6D Donald. labrond (regey Saunders ober land David. Shut, PHO sera: hall, MS Cog Wendy Crk sein olet Dev. Gach, Ph hard Geeoes, PAD we Hash, PRD ‘ehioKowokan Sendra kr, PHD ‘in Wing ti PD Choron Margen Viger Mado, Ess Strives Sina PRD Reber Sum Dave Vesqer Mork Zachos SAE Publications Board Wihes 0. Mody ~ Chie Nehewed Eyed John eer Ronald D, Matos, PAD Alon Nie J Ogee er. Padres David Sout SAE Sections and Affiliate Activities vwnwwoffhighway-online.orgTEXAS dace Pod When you're in the business of making big things happen, you need a hydraulics solutions provider as tough and capable as you are. That's Texas Hydraulics. We've got your solutions. Cote TE h§ 254-778-4701 or } PAE Laka PR ee enol 10 SAE OHE November 8, 2012 Chevrolet Tahoe and GMC Yuken) applic cations since 2008, Lunique design of the electrode tip. ts ‘concentric domed rings (see accompany ing image) break through the aluminum ‘onde layer contained on all aluminum parts. GMs invention is the “that layer is the bane of aluminum welding,” Carson explained. “The rings “ow the electrode to engage the surface af the material so that current passes Frore easly and generates a weld nugget inthe middle, centered between the to parts,” he said The orocess not affected by material qauue and has demonstrated improve gauge fh process consistency ae rents since entered volume produ trode Neon recalled GMs implementa- Ton SSastealy the ME {manufacturing seo neering] guys wanted us to do due Shree, so we tonk the recommended sretccas of The Aluminum Association Tor weld schedules and electrodes and tid process windows v5. our technology. ‘We published this in an earlier sheetmet= al conference papet” “The new electrode tip design ges 2 larger and more robust weld process wine Gow. with much tighter consistency than eth conventional aluminum spot weld ing, Carson noted. “We don't have trad- tTonal issues such as the sheet metal Stcking to the electrode, which usually Freans the welding cel will stoo and the Spperator has to go in and check it out (We avoid all of those interruptions iM PrO= tduction.” GM uses MFDC (midfrequency direct carrent) in its aluminum fabrication operations. Hon Lauckner, GM's Chief Technology officer, views the technology 25 2 state gi asset. "The ability to weld alurinam Body structures and closures in such 3 Tabust fashion wail gue GM a unique manufacturing advantage,” he said in 8 Statement. “Is an important step for yard that will grow in importance 28 WE vherease the use of aluminum in our cat frocks, and crossovers over the next Sev eral years, Lindsay Brooke safety first at S-E-A ‘Vehicle safety and crash worthiness tests sre vital to requlatory bodies around the rorld and subsequently the automotive vy commercial vehicle industries. New sohicle designs and restraints are continue Sly under development, and each new Commercial product needs to be evalu She with respect to standards, regular fions, or claimed occurrences. vafter decades of scientific endeavor, ‘transportation safety testing has evolved fo become an indispensable component Inthe occupant protection process Despite these years of evolution all safety teats and spectficaly roll-over testing have inherent sues that diminish its practical ity and usefulness ‘Most methods of roll-over testing © sult in a destroyed or severely disabled sahicle This type of destructive evalua van can get extremely expensive, esPe Cally when multiple euns are required ‘any additional equipment attached to tat vehicle (cameras, Anthropomorphic Feat Devices, etc) 5 also at risk of need ing repalt or replacement upon comele tion of a single run. Outriggers are Sor times affixed to the sides of a vehicle prevent a complete rolkover, ut thes fypes of tests rarely show the full pict ‘Fire is also a limiting factor. Mans hours are devoted 10 preparing @ ver to be tested, cleaning up the result ress, and readying the next run. MC folkover tests are performed outdo fhours of daylight and risk of inlere weather substantially decrease the 0 per of tests that can be executed in day. finaly, any fair scientific experi must be repeatable. Repeatability, © (nith provided specific input pare vs unlikely under the current metho ‘Naluation, Human factors, 7026 €° tions, and slight differences DeIwe hhcles ate all variables that can Be! sible for needlessly shifting data es 'A void exists fora facilty that evaluate occupant restraint perfor ina rover event in a quick, acc repeatable, and controllable man swithout causing damage to the ¥ swvewoffighwvay-o