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This paper presents two methods of characterizing and describing the formability of tailor welded blanks (TWB). The first method involves using miniature tensile specimens, extracted from TWB weld material, to quantify mechanical properties and material imperfection within TWB welds. This technique combines statistical methods of describing material imperfection together with conventional M-K method modeling techniques to determine safe forming limit diagrams for weld material. The second method involves the use of an extended M-K method modeling technique, which places multiple material thickness and material imperfections inside one overall model of TWB performance. These methods of describing TWB formability and their application to specific aluminum TWB populations are described.

Light-duty pickup trucks have been and are an important growing segment of the US automotive market. Like all other vehicles on the road, they must also do their part to conserve fuel and weight reduction is a vital tool for achieving this goal. Tailgates currently installed on pickup trucks typically weigh over 30 lbs. and weight loss in these panels is very desirable. Recent demographic shifts in truck users has also lead to more interest in light-weighting of components like the tailgate for ergonomic reasons. Manufacturers have reached the limit for light-weighting tailgates using current materials and manufacturing processes. This new concept changes the paradigm. It uses a hybrid system of aluminum and plastic composite materials along with new manufacturing and assembly processes to achieve a significant weight reduction without compromising performance or other desired attributes. This paper describes the design and demonstrates its viability via analysis and test results.

This paper presents the results of an investigation into the material variables that influence the weldbonding of aluminum. The four major variables that were considered in this study were the aluminum alloy, type of adhesive, the presence of a forming lubricant, and the metal surface treatment. To maximize the amount of information gained from this study, a statistical design of experiments was used. The particular design used here is an example of a screening design, in which a relatively small number of variable combinations is investigated to identify those variables that have a strong impact on the measured responses. The responses in this experiment consist of both quantitative measurements and qualitative judgments that must be taken together to interpret the experimental results. The “quantifiable” responses included weld parameters (current and percent heat); nugget diameter; weld quality ratings (based on a subjective rating system); and tensile strength.