| LIVEMAN | This project is closed |
| Advanced Joining Processes for Lightweight Vehicle Manufacture |
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Context In their determination to remain world competitive, UK vehicle manufacturers require novel designs which achieve substantial weight saving. These are required to meet ever increasing demands for greater fuel efficiency, higher vehicle performance and lower emissions. New designs based on the use of high strength steels and non-metallic materials will in turn impose greater demands on the welding and joining processes. Aims The project aims to demonstrate new technology for the production of a new generation of lightweight cost-effective steel vehicles. The programme is working in four main areas:- Improving conventional welding processes using special sensor systems and parameter monitoring instruments. Novel welding and joining processes (adhesives and laser welding). New material forms (tailored blanks and hydroformed tubes). Assessing the performance of prototype designs of lightweight structures. Method The project has established that:- New strength steels with yield strengths >300 MPa are cost effective for vehicle manufacture. Continuous joining processes (continuous welding or adhesive bonding) produce significant increases in structural stiffness. New material forms (tailored blanks and hydroformed tubes) introduce a number of joining issues which must be resolved. Joint quality depends significantly on the accuracy of joint fit and the controllability of the joining process. Suitable alloys and welding parameters for laser joining have been identified. Benefits Vehicle manufacturers will be able to adopt new manufacturing techniques for the production of lighter weight steel vehicles in a cost effective manner. The steel industry will be able to respond to the competitive challenge from light weight metals and plastics. Participants TWI Liverpool University Oxford Brookes University Cambridge University Cranfield University Hawtal Whiting Air Products British Steel ESAB Ford Motor Company Henrob Jaguar Cars GKN Oerlikon Permabond Pre-Star |
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