Innovations for Automotive Light Weight Solutions: The Steel Aluminium Hybrid Blank

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Innovations for Automotive Light Weight Solutions: The Steel Aluminium Hybrid Blank

Arenholz, Enno / Brugger, Gerald / Bruckner, Jürgen

The interest in joining steel with aluminium for innovative solutions in car manufacturing has significantly increased over the past two years. The necessity to save vehicle weight in order to reduce CO2-emissions during the use phase in automotive industry is the driving force for this development. This paper will first summarize the challenges for the thermal joining of the two materials with respect to the formation of intermetallic phases, mechanical properties and corrosion. The solution in form of the Steel Aluminium Hybrid blank will be presented. This includes the fundamentals of the CMT-joining process (Cold Metal Transfer) as well as the voestalpine joining geometry. The properties of the hybrid blank with respect to mechanical characteristics, corrosion, forming capabilities on laboratory and vehicle part scale are shown. Further first experimental results on joining modern AHSS-steel with 5xxx and 6xxx aluminium alloys as well as the optimization of the joining geometry for improved welding velocity and formability are discussed.