Manufacturing Feasibility of Adhesively Bonded Aluminum for Volume Car Production

Following-earlier work on the development of a concept car for the nineties employing a weld-bonded aluminum alloy load bearing base unit, work has continued on this aluminum structured vehicle technology (ASVT) to develop and test the manufacturing feasibility and economics for high volume production. The paper reviews the feasibility of the total manufacturing process highlighting experiences from further work, including developments in aluminum welding technology. The overall economic cost comparison between an aluminum structured vehicle (ASV) and a spot-welded coated steel monocoque vehicle shows that there need not be a cost premium for the aluminum structured car.