22 Dec 2022
Joining methods play a critical role in the BIW industry. It, directly and indirectly, influences critical aspects of the vehicle viz., the weight, fuel consumption, structural integrity, strength, and cost of the vehicle. Joining methods can be thermal (Arc welding, MIG Welding, Laser brazing) and non-thermal (clinching, glueing, riveting, etc.) in nature.
This article will take you through the popular joining methods in the BIW industry viz. Spot Welding, MIG Welding (Arc Welding), Laser Brazing and Clinching
Also called Resistance Spot Welding, spot welding continues to be the main choice of joining processes in the body shop ( it constitutes close to 40% of all joining processes).
Arc welding is one of the most prominent types of welding. Arc processes involve using the concentrated heat of an electric arc to join metal materials (Fusion welding)
MIG Welding is the most widely used arc welding technique in BIW joining. Aluminium parts have been largely joined by means of MIG (Metal Inert Gas) welding in lightweight car manufacturing.
This technique is principally used to make joints between castings, extruded sections, and sheet-metal parts.
MIG welders use a tool called a spool gun, which feeds a spooled wire electrode at a selected speed. The gun also emits a shielding gas as it lays the weld. This gas protects the weld area from atmospheric gases such as nitrogen and oxygen, which can cause problems if they come in contact with the electrode, the arc, or the welding metal.
The final result of an optimal MIG Welding process
A brazed joint is made in a completely different manner from a welded joint. Brazing does not melt the base metals since the temperature is invariably lower than the melting points of the base metals. Brazing temperatures are significantly lower than welding temperatures for the same base metals, using less energy.
A brazed joint has a smooth, favourable appearance compared to a welded joint and reduced cost since there is no need to perform any finishing operations after Brazing is performed.
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