AUTOMOTIVE DESIGN
BONDING TOGETHER
Adam Ward explains how light-weighting techniques allow vehicle manufacturers to respond to industry demands
W
ith strict emission regulations designed to reduce pollution, and consumers demanding vehicles that feature all the
latest modern technologies and better mileage, car manufacturers are faced with a challenge to meet these requirements and remain profitable. In a bid to achieve this, manufacturers have begun to turn to light- weighting techniques, but as mixed materials continue to be used more in vehicles, one of the biggest issues engineers are confronted with is how best to bond materials together.
MAKING LIGHT WORK OF MANUFACTURING Light weighting focuses on reducing the weight of components inside and outside of a vehicle. Traditionally focused on low- volume sports cars or high-end vehicles, efforts are now being applied to mass- produced products and weight reduction
has become an integral part of the design process.
When it comes to bonding materials together on vehicles, mechanical fasteners are a popular choice and have played a central role in car manufacturing for years. However, to address many of the challenges faced today, removing mechanical fixings from a vehicle, and replacing them with a lighter alternative, such as tape, offers a range of benefits.
BONDING TOGETHER TO FIND A SOLUTION One of the main benefits of applying adhesive technology is that the substrate does not need to be thick to accommodate stress points. Tis means that thinner and more lightweight
materials can be used in the process without compromising on design or performance. Adhesive bonding also acts as a sealant and can eradicate many of the issues associated with drilling holes to add fasteners and rivets, such as weakening of the substrate and moisture ingress and corrosion problems. As well as reducing noise, vibration, and harshness (NVH), which is not only annoying to the consumer but represents wasted energy, adhesive tape can also help dissipate energy rather than transmit it.
THE HEAT IS ON It could be argued that traditional thermal bonding techniques such as welding and soldering are still the industry preference due to their perceived value for money and quick turnaround time. However, when you take preparation and other pre-assembly costs into account, this might not necessarily be the case. When applying adhesive technology, production costs and finishing times are often faster. Besides, reworking the bond is easier when it comes to disassembling, reworking, or repair. Another important aspect to bear in mind here is the issues surrounding health and safety. As most adhesives can be applied at room temperature, without the need for intense heat, worker comfort and safety are also improved. However, as with most things in life, it is never as easy as it sounds. Understanding the actual stresses and loads of different adhesives to select the right material for each specific application can be challenging. For this
reason, it is important to choose the strength and durability of the adhesive to suit the individual
requirements of the The type of materials used makes a huge difference in overall weight 6
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substrate and application. Just as there are different metals, alloys, and composites that work best in different parts of the vehicle, there is also a wide variety of adhesive tapes. For example, double-sided, heat-curable, and acrylic foam
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