Services for the automotive industry

Expertise at your service

TWI can provide your company with skills and know-how from a comprehensive range of specialised technical resources.

Body construction - Traditionally cars have been made largely by the resistance spot welding of thin mild steel sheet, with some arc welding of chassis components; larger vehicles have used more arc welding. These processes remain important, and TWI is well equipped to work on them. Indeed, with the introduction of zinc coating, high strength alloy steels and hydroformed components, these technologies still require attention.

However, the automotive world is changing, notably in the need to reduce vehicle mass. TWI, helped by its ability to cross fertilise ideas from other industries, can offer expertise in:

new materials: aluminium, magnesium, polymers, composites;
new joining methods: point joining ( e.g. self-piercing rivets, clinching), laser- friction- and electron beam-welding, adhesive bonding;
joint design for recycling.

Power train and chassis - Modern automotive powertrain design is dominated by the need, driven by governments' commitments under the Kyoto agreement, to reduce the CO ₂ output from vehicles; therefore lower fuel consumption is a primary aim. This is being addressed via improved combustion efficiency, mass reduction and reduction of friction. TWI is well placed to contribute via its expertise in:

lightweight materials: aluminium (already extensively used), magnesium ( e.g. sump pans), non-metallic materials ( e.g. manifolds);
joining of 'difficult' materials: welding of castings, welding of mixed materials, joining of metal and polymer composites, joining of ceramics;
a wide range of surfacing technologies for improved temperature performance, resistance to wear, and friction reduction
the development of a novel material ( Barrikade ^® ) for thermal insulation and fire protection.

Trim and interior - By definition, trim and interior parts of a car have to look attractive and stay looking attractive while, as for the rest of the vehicle, cost reduction has a high priority. In addition, trim and interior parts are increasingly a focus for lightweight technologies. TWI's expertise to serve this complex area covers:

Lightweight materials (plastics, aluminium, magnesium)
Novel, economical and rapid joining methods for traditional and new materials
A unique laser welding method ( Clearweld ^® ) for high speed welding of transparent and other polymers. The Clearweld ^® process was invented, and is the subject of a patent application, by TWI. It is being commercialised by Gentex Corporation. The process uses lasers that are commercially available, and infrared absorbing welding consumables that are currently under development, but the intention is to create a product line of consumables compatible with commercially available delivery systems ( e.g. inkjet inks, inks for liquid dispensing systems, thin films etc)

Electrical components and control systems - Electronics is the biggest growth area in the automobile field. In less that 20 years the electronics content of a car has grown from just a radio, via engine management systems and general management of electrical systems, to the control, of almost everything including, in the not too distant future, brakes and steering. Indeed the high-end car of today already has more electronics than the NASA space vehicles of the Apollo era.

These electronics systems must above all be reliable and, in the face of new legislation, be recyclable. TWI has expertise to support these aims as follows:

encapsulation of electronics for harsh (particularly high temperature) environments;
joining of copper wire and micro-joining for electronics;
recycling of electronics, including bio-degradable materials and lead-free solders.

Automotive Industry Panel

TWI has set up a dedicated industry sector panel to serve the needs of the automotive industry. This panel enables industrial member companies and TWI to discuss current and future requirements for the industry. Subjects covered in this open forum have included:

lightweight vehicles - beyond aluminium
ultra high strength steel - design and joining issues
best practice joining technology
trends in the automotive industry
the substance and conduct of TWI's Core R & D Programme

To ensure an unbiased approach at the forefront of technology, the Panel contains a representative cross-section of the industry:

vehicle manufacturers
parts suppliers - tier 1 and 2 etc
materials suppliers

Support for industry

As an industrial member company you can make use of technical support from TWI in all areas of structural integrity, materials engineering and joining technology. This will enable your company to:

reduce costs/increase profitability
improve quality and reliability
improve repair quality
increase competitive advantage
develop and innovate processes
improve material assessment and selection

Member services

Covering five main areas, TWI's services are designed to complement your activities.

Contract R & D services

Short and long-term R & D programmes are carried out for Industrial Member companies who want to exploit new technology or to resolve problems. This may be through a confidential single sponsored project, a group sponsored or a collaborative project.

Information services

Information covering structural integrity, joining processes and procedures, materials development, inspection, design, automation and manufacturing is provided for Members as one of the benefits of membership.

You have direct and instant access by telephone, or e-mail to TWI's information resources. You could have a technical enquiry, a standards query or want the results of a TWI core research and development programme.

Requests can also be made to the library or the Weldasearch office for any published information on welding and joining technology. Alternatively, the Weldasearch database can be accessed here.

Technology transfer

TWI is actively involved in imparting the knowledge, expertise and experience gained in working for industry since 1946, collaborating with companies of every size to implement appropriate available technology to improve business performance. Technology transfer happens through:

Customer driven technical groups and industry panels
Project reports on key technologies
Training material
TWI journals, newsletters and videos
Conferences, seminars and workshops
The Welding & Joining Society
International Institute of Welding
Input to international standards
JoinIT ^®

Your company can become involved with national and international working groups and a worldwide network of contacts through TWI.

Consultancy and project support

TWI's experts work with industry, applying their unique knowhow from concept to completion. A multidisciplinary approach at TWI means that teams covering a wide range of skills can be brought together to solve problems arising at any stage within a product's life cycle. TWI helps the automotive industry with:

Materials selection and performance
Joining processes
Coatings
Design, safety and reliability
Inspection
Flaw assessment
Repair
Failure analysis
Stress analysis
Mechanical testing
Engineering software
Quality assurance
Health & safety
Process modelling

Training, qualification and personal membership

A properly trained and qualified workforce:

inspires business confidence
meets quality management and contract requirements
promotes product integrity and safety
ensures cost-effective operation
avoids expensive mistakes and litigation

An on-site training centre at Abington has been built to support human resource development for engineering worldwide. All training is closely matched to demands of industry, courses are constantly being updated to encompass new and developing technologies. If you are unable to find a specific course to suit your company's needs, then tailor-made programmes can be arranged, either at your own or at TWI's premises.

Examinations leading to certification under internationally recognised schemes (CSWIP, ASNT and PCN) may be taken at the centre.

Courses have been developed to match the needs of the automotive industry:

resistance welding
practical welder training
materials weldability
essentials of welding design
IIW/EWF Welding Engineer, Technologist, Specialist
appreciation of NDT techniques

Technology projects for automotive

TWI provides support and guidance for the implementation of joining and manufacturing processes. Some of the R & D projects carried out by TWI for the automotive industry include:

analysis of dynamic failures in carbon fibre-reinforced composites, invaluable when assessing the wide variety of composite systems in use and developing new designs
fatigue testing of thin sheet aluminium TIG welds to produce design for the manufacture of more efficient structures.
development of prototype welding equipment for thermoplastic composite structures
shaped metal deposition using a range of welding processes

Projects at the leading edge

Recent work at TWI for the automotive sector

Back-up resources

Member companies have access to the total range of resources at TWI. Extensive laboratory facilities with a wide variety of advanced equipment and specialised test facilities are available, these include:

Finite element analysis
Fatigue and corrosion fatigue
Fracture testing
Material and chemical analysis
NDT
Impact testing
High temperature tests

The next step

For further information contact the Automotive Industry Team ( automotive@twi.co.uk) at TWI for any of the services outlined on these pages, or if your company needs any help with an automotive problem.