Lightweight Body Advancements: Haifei's Joining Solutions
Haifei Welding Systems Advance Automotive Lightweighting:
- Projection Welding for PHS Screws/Nuts
- Application: Front floor tunnel assemblies
- Robotic Resistance Spot Welding Workstations for Aluminum Crash Beams
Driven by carbon neutrality goals, vehicle lightweighting has become critical for EV range extension. Three core approaches enable weight reduction:
① Material Innovation (lightweight alloys & composites)
② Structural Optimization
③ Advanced Manufacturing
Material-Specific Joining Technologies
| Material System | Dominant Joining Methods | Key Processes |
|---|---|---|
| Steel Dominant | Welding (95%) | Resistance Spot Welding (RSW), GMAW |
| Aluminum Body | Mechanical Fastening | SPR, FDS, Adhesive Bonding |
| Steel-Aluminum Hybrid | Hybrid Joining | RSW + MIG + SPR/FDS |
| Multi-Material | Integrated Connection | RSW, Adhesives, SPR/FDS, Laser Welding |
SPR: Self-Piercing Riveting | FDS: Flow Drill Screwing
Haifei's Lightweighting Enablers
1. Press-Hardened Steel (PHS) Solutions
Nut/bolt projection welding for:
✓ Front floor channels
✓ Crash beams (shear strength >12kN)
2. Aluminum Joining Systems
Robotic RSW workstations with:
✓ 200Hz medium-frequency inverters
✓ Electrode force control (±1.5%)
3. Multi-Material Adapters
- CD welders for carbon fiber/steel stacks
- AI-controlled SPR systems
Technical Impact
EV Range Boost: 7% weight reduction → 5% range increase (SAE study)
Joint Efficiency: Aluminum RSW achieves 90% base metal strength vs. 70% with adhesives
*Case: Haifei's 4-station PHS nut welding line increased throughput by 40% at a Tier-1 supplier.*
Automotive Body Materials and Joining Evolution：
Driven by lightweighting demands, body materials have diversified from traditional all-steel structures to multi-material systems, necessitating advanced joining technologies:
- Welding
- Mechanical Fastening
- Adhesive Bonding
