Brigham Young University (BYU) has teamed up with Toyota to develop an advanced welding technique that significantly improves the efficiency of welding aluminium sliding doors on the Toyota Sienna. Traditionally, resistance spot welding, a method suited for steel, has been used for this application. However, the new technique, known as refill friction stir spot welding, has been specifically adapted for aluminium’s unique properties.

Image Souce: Jaren Wilkey, BYU Photo

This innovation comes at a crucial time as car manufacturers increasingly shift towards using lighter aluminium components instead of heavier steel. According to BYU’s research, the new welding process offers substantial benefits: it uses 40 times less energy, generates fewer emissions, and produces welds that are 10 times stronger than traditional methods.

"Toyota has always utilized the cleanest technologies available, but what BYU's research brings to the table is a game-changer," said Yuri Hovanski, a professor of manufacturing engineering at BYU. "They partnered with us to perform side-by-side comparisons of the same model of car, using the new welding technology."

The partnership was initiated after Hovanski presented the innovation at a conference, where it caught the attention of Toyota’s engineering team. Following this, Hovanski, along with graduate student Damon Gale, visited Toyota’s manufacturing plant in Indiana to assess the existing production process and explore how the new technique could be implemented in the production of aluminium sliding doors.

How Refill Friction Stir Spot Welding Works

Unlike traditional welding methods, refill friction stir spot welding does not melt the metal. Instead, it keeps the aluminium in a solid state. The process works by applying pressure and inserting a rotating pin into the metal. The friction generated by the pin softens the metal, allowing it to bond without the need for melting, resulting in a stronger and more durable joint.

This cutting-edge technique holds the potential to revolutionize the way aluminium is used in automotive manufacturing, making vehicles lighter, more energy-efficient, and environmentally friendly.