For new lightweight concepts in car body building, the classical automotive joining techniques, spot-welding and GMA-welding, are no longer sufficient. For joining high strength steels techniques are necessary, that preserve the good crash and service strength of the base materials also for the joint. The combination of different materials requires, in addition, the development of joining processes suitable for multi material joints. High demands on the dimensional tolerances speed up low heat input joining technologies especially for lightweight alloys. The challenge for future automotive joining processes lies, therefore, in the adaptation of existing joining technologies and the development of new techniques and processes not only in the field of welding but also in the field of mechanical joining and adhesive bonding. For arc welding processes (two-wire GMA-welding, AC-MIG welding, GMA-brazing, Plasma-MIG-welding) as well as for beam welding (EBW, Non-Vacuum-EBW, Laser beam welding with filler wire) newly developed process technologies and process variants are presented which increase the field of application, welding speed and efficiency, seam quality and finally result in economical advantages. Modifications of the existing spot welding technology, and efforts in joining of aluminium to steel (material selection, modified GMA welding process, laser assisted brazing) are discussed. Applications of mechanical joining processes and adhesive bonding are given as combining different material types are gaining increasing importance in modern car production. This increases also the necessity of sophisticated simulation tools. A short description in activities of welding modelling is given. Future ambitions result in linking the output of these simulation programs to design and calculation software and planning systems in order to get an overall virtual view of all aspects of automobile design, testing and production.


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