Hirotec America Creates Lightweight, Hybrid Crash Beam With Magnetic Pulse Technology
C3 magnetic pulse welding has a faster cycle time than traditional arc welding, does not use consumable materials, and creates stronger bonds all without heat and sparks.
Posted: February 5, 2008
Hirotec’s C3 magnetic pulse welding is faster and creates stronger bonds than traditional arc welding.
Automotive closure expert Hirotec America (Auburn Hills, MI) has perfected a manufacturing process for a crash beam that achieves a nearly 35-percent weight reduction compared to previous designs.
By using the company’s C3 (Clean, Cost-effective Cold welding) magnetic pulse technology, the traditionally all-steel part now features an aluminum and steel combination made possible through a “cold” weld achieved with concentrated electric pulses. Hirotec America is the first company to take magnetic pulse technology to OEMs and suppliers as a manufacturing solution.
“We have refined a method to build a crash beam from aluminum and steel that can be spot welded directly into current door structures,” said Dr. Jianhui Shang, product specialist, Hirotec America, who developed the process leading to the advancements shown in the crash beam. “Magnetic pulse technology trims weight by incorporating lighter materials and with today?s focus on fuel efficiency, weight reduction is key. Magnetic pulse welding allows dissimilar metals to be bonded together on a molecular level?a process that couldn?t be done before.”
The crash beam provides the necessary strength by using spot-welded steel on the sides and aluminum in the main structure solving a long-time manufacturing challenge of reducing weight while still providing the required levels of impact resistance.
“We are inventors,” said James Toeniskoetter, president of Hirotec America. “We’re constantly developing new assembly technology to solve the issues facing our customers?especially those related to closures.” Hirotec America’s parent company, Hirotec Group, is the world’s largest independent producer of automobile doors, with 6 million produced annually.
C3 magnetic pulse welding has a faster cycle time than traditional arc welding, does not use consumable materials, and creates stronger bonds all without heat and sparks. The C3 process also produces quality products at a higher yield because no pre-or post-processing is required; is clean because there is no stamping lubrication involved and minimal burr; and features minimal spring-back and repeatable quality, leading to the development of superior products.
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