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Advantages and challenges of dissimilar materials in automotive lightweight construction

The core of future automotive lightweight materials is the joining technology of various material mixes. The type of joining will be essential, particularly in electrified propulsion systems, especially as an improved electrical energy transmission leads to a higher total efficiency of the vehicle. The most evident parts to start the optimization process are the traction battery, the electrical performance modules and the engines. Consequently aluminum plays a very central role for lightweight construction applications. However, the physical-technical requirements of components often require the combination with other materials. Thus the joining of mixed material connections is an essential key technology for many of the current developments, for example in the areas E-Mobility, solar energy and lightweight construction. Due to these advantages mixed material joints are already established in the automotive industry and laser beam remote welding is now a focus technology for mixed material connections. The secret of the laser welding process with mixed materials lies within the different areas of the melting phase diagram depending on the mixing ratio and the cooling down rate. According to that areas with unwanted, prim, intermetallic phases arise in the fusion zone. Therefore, laser welding of mixed material connections can currently only be used with additional filler in the automotive industry.