Joining Technologies and Solutions for Aluminum-based Battery Case Manufacturing

Recently, considerable research has been conducted to identify suitable replacement for aluminum material used in producing lightweight car bodies, and accordingly, various welding processes have investigated. However, no optimize joining through experimental comparisons of the fastening battery cases hybrid electric vehicle. Therefore, this study a joint quality comparison nine overlap 1.2 mm thick Al5052-H32 material. The tested were self-piercing rivet(SPR), arc welding, refill friction stir spot welding(FSSW), laser adhesive bonding, clinching, joining, flow drill screw(FDS). test results assess manufacturing based on OEM production guidelines field application. Each process was evaluated terms investment cost, strength, endurance, productivity, weldability under different weight factors. SPR most competitive among processes, FSSW, considered alternative choices aluminum-based case manufacturing. By contrast, resistance FDS determined be challenging use as primary processes.