GM: New aluminum welding technology to increase vehicle fuel efficiency
DETROIT, MI- In an effort to improve the fuel efficiency of its vehicles, General Motors Co. plans to use a new aluminum welding technology "more extensively" starting next year.
According to the Detroit-based automaker, the resistance spot welding process, which GM says is an industry-first, is expected to enable more use of the lightweight metal on future vehicles, which can help improve a vehicle's miles per gallon and driving performance.
“The ability to weld aluminum body structures and closures in such a robust fashion will give GM a unique manufacturing advantage,” said Jon Lauckner, GM chief technology officer and vice president of Global R&D.
GM already uses this patented process on the hood of the Cadillac CTS-V and the liftgate of the hybrid versions of Chevrolet Tahoe and GMC Yukon.
According to AluminumInTransportation.org, a 5 percent to 7 percent fuel savings can be realized for every 10 percent weight reduction.
“It is an important step forward that will grow in importance as we increase the use of aluminum in our cars, trucks and crossovers over the next several years,” Lauckner said.
Historically, automakers have used self-piercing rivets to join aluminum body parts. However, rivets add cost and riveting guns have a limited range of joint configurations.
GM’s new welding technique works on sheet, extruded and cast aluminum that uses a multi-ring domed electrode that welds aluminum to aluminum.
“No other automaker is spot-welding aluminum body structures to the extent we are planning to, and this technology will allow us to do so at low cost,” said Blair Carlson, GM manufacturing systems research lab group manager.
Carlson said GM may license the technology for non-GM production in automotive, heavy truck, rail and aerospace applications.
According to officials, aluminum use in vehicles is expected to double by 2025, when the recently finalized vehicle fuel economy standards will nearly double to 54.5 miles per gallon in the next 13 years.
Aluminum is a lightweight, soft, low strength metal which can easily be cast, forged, machined, formed and welded. Unless alloyed with specific elements, it is suitable only in low temperature applications. Aluminum is readily joined by welding, brazing, and soldering. In many instances, aluminum is joined with the conventional equipment and techniques used with other metals. However, specialized equipment or techniques may sometimes be required. Aluminum welding st louis
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