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A series of laboratory experiments were conducted to determine the ability of acoustic and thermographic methods to evaluate the quality of individual spot welds and the structural integrity of spot-welded joints with and without adhesive. Test specimens consisted of spot-welded, adhesive-bonded, and weld-bonded lap joints in steel plates. The quality of the spot welds was altered by varying welding parameters. After nondestructive evaluation, the samples were peeled or subjected to mechanical tests to determine the strength of the welds. Results demonstrate that it is possible to detect defective spot welds in both the thermographic and acoustic images. Techniques are presented that allow identification of “stick” welds characterized by solid but weak contact. Methods to quantify the imaging results are being developed by comparing the acoustic and thermographic images to the data obtained from mechanical strength tests and modeling results.

Advanced lightweight insulation and window technologies can contribute significantly to achieving industry and government goals of substantially improving fuel economy without loss of vehicle performance or passenger comfort. Two conventional passenger automobiles, a 2001 sport-utility vehicle (SUV) and a 1999 mid-size sedan, were retrofitted with lightweight insulation; the sedan was also fitted with specially designed windows. The body insulation and windows reduce heating and cooling loads, which allows downsizing of heating, ventilation, and air conditioning (HVAC) equipment. Benefits derived from the use of advanced insulation and window technologies include: Demonstrated reductions in cooling loads; Fuel savings for conventional and hybrid vehicles; Extended range for electric vehicles; Greatly improved passenger comfort; Reduced degradation of interior surfaces; and Improved safety.