Free Online Manual for Automotive Aluminum Joining

Ann R. Thryft

March 18, 2015

2 Min Read
Free Online Manual for Automotive Aluminum Joining

A new online manual that describes in detail the range of commercial technologies for joining automotive aluminum components is available free from the Aluminum Association. It was developed in response to the growing needs of automotive engineers and designers, who are using more aluminum alloys and multi-materials assemblies in their designs.


The multi-chapter 2015 Automotive Aluminum Joining Manual was developed in collaboration with the European Aluminium Association (EAA) and the US-based Aluminum Extruders Council (AEC). The EAA has already published a complete Aluminium Automotive Manual, and had started on a joining update when the US groups began their work on automotive joining. The goal was to create a manual coordinated between the two regions, so the project became co-sponsored, Joseph A. Golec, vice president of sales & marketing for Pennex Aluminum, told Design News. Golec is also chairman of the AEC Automotive Industry Promotion Committee, and was instrumental in coordinating the technical review of the manual from the extrusion side.

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Engineers can access the manual online from the website of the Aluminum Association's Aluminum Transportation Group here. It's also available as part of the full EAA automotive aluminum manual, which you can find here.

The book-length manual covers the joining of aluminum to aluminum, as well as joining aluminum to other common automotive materials, such as steel, plastics, composites, and magnesium. It contains 11 chapters: Introduction, Characteristics of fusion welding, Arc welding (available soon), Beam welding, Resistance welding, Brazing, Solid state welding, Mechanical joining, Adhesive bonding, Hybrid joining, and Joining dissimilar materials. In each of these, engineers and designers are given a detailed technical reference that outlines the benefits, design implications, and potential limitations of each method.

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"The decision to provide this kind of information was driven by an overwhelming request from the automotive engineering world about how do we join these materials," said Golec. "How do we join an extrusion to a casting or a sheet? How do we join any of these to any other? And how do we join aluminum to other materials? These have been joined before in a non-automotive environment, but the automotive industry has its own needs. This information is probably the most sought-after that aluminum extruders and the AEC see requests for, especially in automotive."

Ann R. Thryft is senior technical editor, materials & assembly, for Design News. She's been writing about manufacturing- and electronics-related technologies for 25 years, covering manufacturing materials & processes, alternative energy, machine vision, and all kinds of communications.

About the Author(s)

Ann R. Thryft

Ann R. Thryft has written about manufacturing- and electronics-related technologies for Design News, EE Times, Test & Measurement World, EDN, RTC Magazine, COTS Journal, Nikkei Electronics Asia, Computer Design, and Electronic Buyers' News (EBN). She's introduced readers to several emerging trends: industrial cybersecurity for operational technology, industrial-strength metals 3D printing, RFID, software-defined radio, early mobile phone architectures, open network server and switch/router architectures, and set-top box system design. At EBN Ann won two independently judged Editorial Excellence awards for Best Technology Feature. She holds a BA in Cultural Anthropology from Stanford University and a Certified Business Communicator certificate from the Business Marketing Association (formerly B/PAA).

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