Review Article: Joining Technologies for Lightweight Automotive Structures

Abstract

One of the most crucial sectors for society and economic development is the transportation sector. This is particularly true for road transportation everywhere, which is a vital component of trade, employment, and economic growth. The difficulty lies in maximizing efficiency and minimizing expenses and energy while maintaining safety and comfort. This is the impetus behind technology advancement, which is transforming the movement of people and products in tandem with societal shifts (such as shifting consumer preferences and increased environmental consciousness) and political shifts. However, the choice of lightweight materials is minimal; innovative joining and manufacturing technologies may be used. Since 2003, Jaguar Land Rover (JLR) has been one of the leading automakers using aluminum alloys. 90% of the aluminum stamping components of a typical JLR monocoque are composed of aluminum alloys from the 5xxx and 6xxx series. An alternate interpretation of enhanced lightweight frame architecture is the Audi Space Frame (ASF), which is distinguished by its more than 80% aluminum content and CFRP residuals utilized for the tunnel, rear panels, and components that contribute to increased torsional stiffness. Compared to equivalent elements made of conventional steel, a 30% weight reduction is achieved. With the aim of lowering bulk and enhancing sustainability without raising costs or compromising safety, this analysis provides a broad overview of the potential and problems facing automotive body structures in the upcoming years. In order to minimize carbon emissions and create recyclable constructions, this paper first assesses ways to reduce vehicle bulk. Given the design limitations and the technology selection, the potential of novel materials will be demonstrated. The prospects for engineering innovation brought about by this time of significant needs and change will be covered in the closing remarks.