TAILOR WELDED BLANK

APPLICATIONS AND MANUFACTURING

A State-of-the-Art Survey

The Auto/Steel Partnership

Tailor Welded Blank Project Team
2000 Town Center - Suite 320
Southfield, MI 48075-1123
June 2001
 Auto/Steel Partnership

Bethlehem Steel Corporation

DaimlerChrysler Corporation
Dofasco Inc.
Ford Motor Company
General Motors Corporation
Ispat Inland Inc.
LTV Steel Company
National Steel Corporation
Rouge Steel Company
Stelco Inc.
U. S. Steel Group, a Unit of USX Corporation
WCI Steel, Inc.
Weirton Steel Corporation

This publication is for general information only. The material contained herein should not be used without first
securing competent advice with respect to its suitability for any given application. This publication is not intended
as a representation or warranty on the part of Auto/Steel Partnership – or any other person named herein – that
the information is suitable for any general or particular use, or free from infringement of any patent or patents.
Anyone making use of the information assumes all liability arising from such use.

For more information or additional copies of this publication, please contact the Auto/Steel Partnership, 2000
Town Center, Suite 320, Southfield, MI 48075-1123 or phone: 248-945-7777, fax: 248-356-8511, web site:
www.a-sp.org

Copyright 2001 Auto/Steel Partnership. All Rights Reserved.

ii
 TABLE OF CONTENTS

EXECUTIVE SUMMARY.............................................................................................................................. 1
3.1.1 INTRODUCTION ............................................................................................................................. 3
1.1 STUDY OBJECTIVES AND SCOPE ...................................................................................... 3
1.2 CONTRIBUTORS ................................................................................................................... 4
3.1.4 TAILOR WELDED BLANK APPLICATIONS ................................................................................. 5
2.1 APPLICATION DESIGNS................................................................................................... 5
3.1.5 STRAIGHT LINE........................................................................................................ 6
3.1.6 NON-LINEAR ............................................................................................................. 8
3.1.7 PATCH ..................................................................................................................... 11
3.1.8 TUBES ..................................................................................................................... 13
2.1.6 HIGH STRENGTH STEEL....................................................................................... 16
2.2 NORTH AMERICAN APPLICATIONS.............................................................................. 16
2.3 EUROPEAN APPLICATIONS .......................................................................................... 19
2.4 JAPANESE APPLICATIONS............................................................................................ 22
3.1.9 WELD PROCESSING TECHNOLOGIES ..................................................................................... 26
3.2 WELDING POWER SOURCE.......................................................................................... 26
3.2.1 INTRODUCTION ..................................................................................................... 26
3.1.2 CO2 AND Nd:YAG ................................................................................................... 27
3.1.3 PLASMA AUGMENTED LASER WELDING (PALW).............................................. 28
3.1.4 INDUCTION AND NON-VACUUM ELECTRON BEAM .......................................... 28
3.1.5 MASH WELDING..................................................................................................... 28
3.2 DUAL SPOT WELDING (MULTI-SPOT) .......................................................................... 30
3.3 EDGE & BLANK PREPARATION .................................................................................... 30
3.4 WELDING PARAMETERS ............................................................................................... 32
3.5 TAILOR WELDED BLANK FORMABILITY ..................................................................... 32
3.5.1 INTRODUCTION ..................................................................................................... 32
3.5.2 FORMABILITY TESTING: PARALLEL AND TRANSVERSE MAJOR STRAIN...... 33
3.5.3 WELDING AND WELD PROFILE............................................................................ 33
3.6 DEFECTS AND DEFECT DETECTION........................................................................... 34
3.6.1 WELD QUALITY ...................................................................................................... 34
3.6.2 WELD GEOMETRY ................................................................................................. 34
3.6.3 POROSITY AND PINHOLES .................................................................................. 35
3.7 WELDING PATCH BLANKS................................................................................................. 36
4.0 MANUFACTURING SYSTEMS AND SUPPLIERS ............................................................................. 37
4.1 MANUFACTURING SYSTEMS - PRODUCTION................................................................. 37

iii
 5.2 INTEGRATED LASER CUTTING AND WELDING (RESEARCH)...................................... 43
5.3 TAILOR WELDED BLANK SUPPLIERS ............................................................................. 48
5.4 NORTH AMERICA............................................................................................................ 48
4.3.2 EUROPE ........................................................................................................................ 48
5.5 ASIA.................................................................................................................................. 50
5.6 SUPPLY LOGISTICS ........................................................................................................................... 51
5.7 PALLETS............................................................................................................................. 51
5.8 INVENTORY ....................................................................................................................... 51
5.9 DIMPLING............................................................................................................................ 52
5.4 STACK REQUIREMENTS ................................................................................................... 52
5.5 OTHER................................................................................................................................. 53
6.0 APPENDIX ............................................................................................................................................. 1
6.1 EQUIPMENT SUPPLIER CONTACTS.................................................................................. 2
6.2 BLANK SUPPLIERS - NORTH AMERICA ............................................................................ 3
6.3 BLANK SUPPLIERS - EUROPE............................................................................................ 5
6.4 BLANK SUPPLIERS - SOUTH AMERICA............................................................................. 7
6.5 BLANK SUPPLIERS - ASIA................................................................................................... 8
6.6 BIBLIOGRAPHY .................................................................................................................... 9

iv
 List of Illustrations

Figure 1 - Worldwide breakdown of TWB applications. .............................................................................5

Figure 2 - B-pillar example of simple, one straight line weld application. ..................................................6
Figure 3 - Multi-straight line welded body side for Jeep Grand Cherokee. ................................................7
Figure 4 - Multi-straight line weld door inner (VW Golf). ............................................................................7
Figure 5 - Angular straight line weld on door inner. ...................................................................................8
Figure 6 - Non-linear prototypes produced by Fraunhofer. ........................................................................9
Figure 7- First known non-linear production TWB - produced by Laser Welding International. .............10
Figure 8 - Analysis of different door designs (Thyssen Krupp Stahl).......................................................10
Figure 9 - Curvilinear wheelhouse developmental application.................................................................11
Figure 10 - Two examples of patch-type tailor welded blanks. ..................................................................12
Figure 11 - Patch TWB comparison for door inner.....................................................................................13
Figure 12 - Four tube shapes: cylindrical, tailor shape, oval, and conical. ................................................14
Figure 13 - Tailor welded tubes: constant OD, constant ID, and “sleeve”. ................................................15
Figure 14 - Soudronic Soutube welding videos..........................................................................................15
Figure 15 - Soudronic Soutube welding unit for tailor tubes. .....................................................................16
Figure 16 - Projected tailor welded blank demand for North America – based on two sources ................17
Figure 17 - North American body side with over 4.8 meters of weld. ........................................................17
Figure 18 - ULSAB tailor welded blank applications. .................................................................................18
Figure 19 - Estimated worldwide TWB demand (in parts produced). ........................................................19
Figure 20 - Distribution of European applications by type and quantity.....................................................19
Figure 21 - Peugeot body side with “short” welds. .....................................................................................20
Figure 22 - BMW 3-series door inner. ........................................................................................................21
Figure 23 - The Toyota Camry body side outer (top), and the Toyota Crown body side inner (bottom). ..23
Figure 24 - Nissan TWB body side (1998 production start). ......................................................................24
Figure 25 - Nissan body side outer panel with high strength steel. ...........................................................24
Figure 26 - Comparison of Four Welding Methods. ...................................................................................29
®
Figure 27 - Soudronic SOUKA process for edge preparation. .................................................................31
Figure 28 - Special blank die design for precise edge condition used at Nissan.......................................31
Figure 29 - Failure patterns for tailor welded blanks. .................................................................................33
Figure 30 - Typical process monitoring approach for potential defect identification. ................................35
Figure 31 - Soudronic laser shuttle system................................................................................................38
Figure 32 - Soudronic SOULAS welding system video..............................................................................38
Figure 33 - Thyssen Conti flow-through system (with jig pallets)...............................................................38
Figure 34 - Schematic of indexing jig/shuttle system with parallel turnover and stacking stations............39
Figure 35 - Schematic of Renault Automation indexing jig system with 2-axis weld capability. ................40

v
 List of Illustrations - Continued

Figure 36 - Nissan TWB welding system development strategy...............................................................41

Figure 37 - Nissan Generation III welding system. ....................................................................................41
Figure 38 - NissanGeneration III video.......................................................................................................42
Figure 39 - Layout of Thyssen non-linear welding line that uses jigs. .......................................................43
Figure 40 - Conceptual Fraunhofer welding system with two CO2 laser resonators – one for blank cutting
and one for welding. ...........................................................................................................................44
Figure 41 - Standardized steel pin pallets used by Mercedes Benz. .........................................................51
Figure 42 - Oblong embossment design that tends to hold up well. ..........................................................52

Table 1 – Comparative tradeoffs between welding technologies. ......................................................... 26

Table 2 – Process control variables for CO2 laser welding (Soudronic results) ..................................... 27

Table 3 – Commercially Available TWB Welding Systems .................................................................. 46

Table 4 – Proprietary TWB welding systems. ..................................................................................... 47

vi
 EXECUTIVE SUMMARY

The tailor welded blank (TWB) industry continues to experience steady growth. Each auto company now
has TWB applications and the growth rate is approximately 25% to 30% per year in North America,
Europe and Japan. The leading objectives continue to be cost reduction, structural improvement and
mass reduction. Certain companies continue to recognize quality improvements as a major objective,
especially with door inners and one-piece body side TWBs. While there continue to be numerous small
(under 0.75 meters), simple, one-weld applications, the growth is spreading into larger, more complex
products. The leading TWB users, GM, DaimlerChrysler, Volkswagen and Toyota, all have door inner
TWBs which were once considered an advanced application because of weld lengths exceeding one
meter. Today, Mercedes, Volkswagen, and BMW have TWB door inners with multiple welds. GM,
DaimlerChrysler, and Toyota are leaders in body side aperture TWBs. There is interest in Europe and
among other Japanese companies, with Nissan having one in production, and looking at more, and
Mazda planning one in the future. Japanese and European aperture designs tend to be markedly
different than those seen in North America. The North American apertures tend to be a body side with
multiple, long welds that are costly to process and weld. European and Japanese designs tend to be
body side inner panels with two to three short welds on shallow draw panels that are simpler to process.
The shallow draw panels are also more conducive to integrating high strength steel into the body side.

The greatest interest in non-linear welding (NLW) exists among North American companies, with some
interest in Europe. Many Japanese companies are content to exploit the simpler, low-risk applications
before "stretching" the technology when minimal additional benefit is gained. Nissan expressed some
interest in NLW parts in the future and have designed their Generation III welding system with NLW
blanks in mind.

The simplest NLW designs involve circular arcs that may or may not be combined with straight lines. The
only known production NLW applications today involve circular arcs in shock tower and floor pan
applications. Multiple straight-line welds, or two straight lines that intersect at an angle are being
produced with current production technology. In some cases, there is a blow-hole at the intersection
point requiring a careful consideration for weld line placement in the design phase. Although technically
feasible, there are no known “undefined” NLW applications in production. In general, this design requires
a sophisticated multi-axis weld head along with equally complex seam tracking software. A key technical
difficulty involves maintaining a constant angle and speed of the laser beam, even around curves, which
requires a weld head employing changing acceleration. Other challenges include obtaining an
acceptable edge fit-up and developing appropriate clamping hardware. Although there is considerable
interest in the benefits of NLW, such as further material and cost optimization and moving the weld line
out of critical forming areas, most OEMs can only justify a marginal cost premium, achievable today only
with simple, circular/arc welds.

The expanded definition of TWBs includes both tailor welded tubes (TWT) and patch-type TWBs. TWTs
are thin-walled tubes with varying wall properties, such as differing thicknesses along the tube. TWT
fabricating technology is available today, but economically viable applications have not yet been
identified. TWTs would most likely be formed with hydroforming; however, both TWT production and
hydroforming processes add considerable expense. As with tube hydroforming in general, design
engineers have to address how the tube will be integrated into and joined with the rest of the body
structure. It’s expected the TWTs will not approach the demand levels of conventional TWBs, but the
demand may be beginning with the first application seen within the next few years.

Patch-type TWBs are in production today, but with very few applications. Two such applications were
observed at one OEM. Patch-type TWBs involve overlaying one blank of steel on top of another, or
overlapping the blanks, and then joining them, usually with spot welds. A minimal number of spot welds
are used and are located in flat, minimally formed areas of the part. Additional spot welds can be added
later in a weld respot line. Advantages of this concept are that the welding is simple and readily able to
be produced in-house at the stamping facility. Second, the fit-up of the two parts is very good since they

1
both are formed together in the same die. Reinforcement tooling can be eliminated and respot welding of
the patch is simplified.

Lasers continue to be the dominant TWB welding technology. There is significant momentum to
investigate the advantages provided by YAG over CO2 laser in the area of process flexibility, or beam
delivery, and edge-fit-up robustness. With YAG prices falling and available power increasing, YAG shows
considerable promise over the next few years. Several producers of TWBs even indicated the probability
of changing from the CO2 processes to YAG in their next generation of welding lines.

Standard weld process control technologies focus on three-level technology:

• The first level tracks edge fit-up quality prior to welding. Edge gap and mismatch can be
detected.
• The second level involves monitoring the weld itself, usually by measuring the weld plume, which
provides an indirect measure of weld quality in that it is not a 100% accurate predictor of weld
quality.
• The third level is to measure the weld after it is completed. Weld geometry can be measured, or
ultrasonic technology can be used to detect porosity and pinholes.

Although it is critical to not send defective parts to the customer, these technologies seem to work fairly
well. Control limits can be stringent and flag suspect panels for manual inspection to minimize the
likelihood of shipping defective panels.

Edge preparation approaches continue to differ by welding process. The major approaches involve:
• Blank die preparation OF up to 1.3 meters in edge length,
• Precision shear,
• Laser cutting.
• Cold working, or SOUKA mash edge process prior to weld,
• Twin-beam power delivery to melt more steel into the gap, and

The blank die approach is the most common and sought after approach for achieving edge fit up. Even
though the small tool clearance in the blank die requires additional maintenance over conventional
shearing, this cost is significantly less than the alternatives. The limitation, however, appears to be just
over one meter, after which straightness and shear/break quality deteriorate the weld edge. Laser cutting
provides an excellent edge fit, which supports rapid welding speeds and complex shape fit-up. Laser
cutting, however, is expensive, and there are no known systems in production. No inherent problems
have been cited with the SOUKA, precision shear or twin-beam processes

2
 3.1.1 INTRODUCTION

1.1 STUDY OBJECTIVES AND SCOPE

The charter of this state-of-the-art study was to identify current and projected developments in Tailor
Welded Blank (TWB) applications and manufacturing technologies. The TWB designation is used in the
broad sense to include conventional TWBs, two or more sheets of steel welded along adjacent edges as
flat blanks prior to forming, tailor welded tubes (TWT) of multi-gage or grade side-walls, and patch-type
TWBs, or a steel "patch" overlapping another steel blank. Although the conventional joining method has
been either CO2 and YAG laser or resistance mash welding, other joining methods were also considered,
including spot welding in the case of patch-type TWBs. Applications and technologies of interest in the
study include current and near-future possibilities.

The majority of weld systems and applications investigated are in production today. All systems are
evolving as welding experience is gained and product applications evolve in complexity. The dominant
welding technology was confirmed to be shifting more toward laser from resistance mash seam, with a
significant focus on YAG laser because of its overall operating robustness and flexibility for non-linear
requirements. Applications are also becoming more complex with longer weld lines, as on door inner and
body side aperture panels, steels that are more difficult to weld, and non-linear weld seams. A significant
aspect of this study included exploring the application interests and state of technology development in
these areas throughout North America, Europe, and Southeast Asia, primarily Japan.

One objective of this investigation was to evaluate the direction of TWB applications and welding
technologies to help guide research initiatives. The TWB industry has evolved rapidly over the past ten
years with major developments in:
• Broad expansion of the supply base,
• High-power welding sources,
• Varied edge preparation techniques for butt welding, and
• Flexible welding systems utilizing beam switching, flexible jigs, etc.

In spite of the industry’s steady growth with “easier-to-justify” applications, the North American automotive
and steel companies recognize that long-term continued growth would require improved product and
process optimization. TWB supply costs are a major barrier to implementation because of welding costs
and the logistical costs of inventory, material handling, shipping, etc. Weld cost can be reduced through
improved edge preparation technologies, increased weld system throughput, or increased welding
speeds and processing efficiencies, and by better product design in light of the varied processing
requirements seen across the supply base. In practice, different companies have taken a variety of
approaches to reduce logistical costs. The Japanese have integrated significant portions of their TWB
welding supply with their in-house blanking and stamping operations to reduce inventories, material
handling and damage while improving communication. Several European companies have developed
standard practices for packaging and pallet design to reduce material handling costs and damage. In
North America, a number of companies are developing technologies that can develop precise edge fit-up
and perform non-linear welding (NLW). NLW allows for refinements in material utilization, mass reduction
and forming complexity in many applications.

Another purpose of this study is to learn about TWB application design and welding technologies to help
further advance the North American TWB supply industry. The principal sources of information for this
study were public literature references, individual interviews, site visits and company-supplied
documentation. Information or developments that companies did not want to publicly disclose were not
pursued for inclusion with this study. The Auto/Steel partnership wishes to thank the companies and
individuals that provided material for this report.

3
1.2 CONTRIBUTORS

3.1.2 AUTO/STEEL PARTNERSHIP TAILOR WELDED BLANK PROJECT TEAM MEMBERS

Cindy Alflen DaimlerChrysler Corporation

Donald Anderson General Motors Corporation
Peter Badgley Stelco Inc.
Karen Bayus General Motors
Jay Baron University of Michigan/ERIM
Jeremy Bennett AK Steel Corporation
Ravir Bhatnagar Ispat Inland Inc.
Paul Bucklin DaimlerChrysler
Ron Carpenter Ford Motor Company
Dawn Castelli DaimlerChrysler Corporation
Geoffery Cooper Ford Motor Company
Stephen Davis Ford Motor Company
Dionisyj Demianczuk LTV Steel Company
Theodore Diewald Auto/Steel Partnership
Larry Du Bois General Motors Corporation
Mariana Forrest DaimlerChrysler Corporation
Mark Garnett DaimlerChrysler Corporation
Charles Gregoire National Steel Corporation
Kris Gregory Ford Motor Company
Bruce Hartley National Steel Corporation
Darrin Keener General Motors Corporation
Alex Konieczny U.S. Steel Group
Andrew Lee Dofasco Inc.
Bernard Levy Ispat Inland Inc.
Sean Martin Dofasco Inc.
William Marttila DaimlerChrysler Corporation
Raj Mohan Rouge Steel
Jack Noel Auto/Steel Partnership
Stanley Pilchowski DaimlerChrysler Corporation
Vasu Rao AK Steel Corporation
Wei Wang Rouge Steel Company
Susannne Wilson Stelco, Inc.
Connie Yao DaimlerChrysler

3.1.3 PARTICIPATING COMPANIES

ATB Bunschoten, Netherlands

AWS Ontario, Canada
Ford Research Center Aachen, Germany
MakAuto Ontario, Canada
Medina/Shiloh Industries Medina, Ohio
Noble Industries Detroit, Michigan
Olympic Laser Processing Belleville, Michigan
ProCoil Canton, Michigan
Prototech Laser Fraser, Michigan
Renault Automation Evry, France
Soudronic Neftenbach, Switzerland
Tailor Steel Genk, Belgium
Tailor Steel of America Holt, Michigan
Thyssen Krupp Stahl Duisburg, Germany
TWB Monroe, Michigan
VIL Chicago, Illinois

4
 3.1.4 TAILOR WELDED BLANK APPLICATIONS
2.1 APPLICATION DESIGNS

The uniqueness of TWB applications found globally is driven more by the differences in application
objectives than by the technical capabilities of available welding systems. Door inner panels, most with a
single weld from top to bottom, are the dominant application worldwide and are usually driven by one or
more of the following:
• Cost reduction
• Structural improvement
• Mass reduction

The objective of a specific application affects the design. More sophisticated door designs are seen in
Europe where structural objectives are more common and volumes are somewhat smaller than in North
America. Rails and pillars are also more common in Europe than in North America because of crash
behavior and, to a lesser extent, mass reduction. A common North American application is the body side
inner, usually with several straight line welds, with a primary objective of mass reduction. The longest
welds are generally found in North America, again on the body sides. The longest documented weld on a
TWB is 2.2 meters on a North American body side.

Soudronic Ltd. Conducted a survey in 1998 that summarized the worldwide applications based on
percentage of market share and weld seam length. Although not shown in Figure 1 below, the majority of
applications consisted of a single straight-line weld.

All applications, present and future, can be categorized as one of the following:
• Single straight line
• Multiple straight line and angular
• Non-linear (curvilinear) – circular arc and undefined
• Patch
• TWB tubes
Market Share (percent)

Doors
30

20 Tunnel &
Pillars Wheelhouse
Rails Floors & Siderings
10
Floors & Siderings (NLTB)
Doors (NLTB)
0
0 500 1000 1500 2000 2500
Seam Length (mm)

Data provided by Soudronic

Figure 1 – Worldwide breakdown of TWB applications.

5
3.1.5 STRAIGHT LINE
Simple, one straight-line weld applications are the most common worldwide. These applications
are simple to weld when the weld length is short, less than 1.3 meters, and if the two blanks have
differing thicknesses as most do. Applications of this type include:
• Front door inners;
• Rear door inners, with shorter welds than the front door;
• Longitudinal rails;
• Pillars, with the B-pillar as the most common;
• Cross rails;
• Reinforcements; and
• Other applications such as floor pans, rocker panels, shock towers, wheelhouse inners,
sill panels, etc.

Typical objectives for these applications include cost reduction, mass reduction, and structural
improvements. An example of a single straight-line part is shown Figure 2 below, a Japanese B-
pillar application.

1.8mm
(440 MPa)

1.2mm
(440 MPa)
weld = 400mm

Major Objective: mass reduction

Figure 2 – B-pillar example of simple, one straight line weld application.

2.1.2 Multiple Straight Line and Angular

Multiple, straight line welded blanks have two or more straight welds. (Figures 3 and 4 on Page
7) Some blanks have two to three welds in the same axis, in-line, and others have parallel welds
or welds in different axes, perpendicular or at angles to the first weld. Demand for applications
with multiple straight lines is increasing, not only for body sides, but for engine rails as well. The
objective for most body side applications is cost and mass reduction, while engine rails have
structural objectives including crash management. General Motors had nine multiple straight line
welded body sides in production in 2000 and one multi-weld underbody cross sill (Ref. 95).
Renault Automation indicated that the main objective for developing their multi-axis jig system

6
was for the Renault demand for multiple straight line welded blanks (Ref. 10) now and into the
future.

Figure 3 – Multi-straight line welded body side for Jeep Grand Cherokee.

1.0mm

1.75mm

1.5mm

hinge side

Figure 4 – Multi-straight line weld door inner (VW Golf).

7
 Angular straight line welds offer a compromise in benefit over non-linear welds without the
welding complexity. Edge fit-up is usually simpler than with curved welds and many of the mass
and structural benefits can still be achieved. Systems that provide angular straight line welds
often produce a blow-hole at the intersection, often located in a spot that will be trimmed out in
the stamping process. Figure 5 below shows a door inner application with an angular weld that
includes a weld line approximately perpendicular to the material flow in the binder at both ends.

Figure 5 – Angular straight line weld on door inner.

3.1.6 NON-LINEAR

The market for non-linear TWBs is smaller than that for conventional blanks because the
incremental cost is difficult to offset by the marginal advantages. There may be cases, however,
where a curved weld is needed because of structural or formability requirements that can
determine whether or not an application is feasible. Figure 6 on page 9 depicts prototype efforts
in this area.

8
 (Shock Tower) Prototype
non-linear tailor welded
blank with high strength
steel center.

(Door Inner) Prototype

non-linear tailor welded
blank.

Figure 6 - Non-linear prototypes produced by Fraunhofer.

Several non-linear, or curved, TWBs have been conceived, but few have reached the
development stage. The first non-linear production TWB was made by Laser Welding
International of Fraser, MI, formerly Prototech Laser, and is illustrated in Figure 7 on page 10.
Thyssen Krupp Stahl of Duisburg, Germany, has researched the advantages of non-linear, or
curvilinear, welding on door inner panels (Ref 113) and believes that curvilinear door inners will
be in production in Europe in the near future (Figure 8, page 10). One advantage of a curvilinear
weld over a multiple straight-line weld is that there is no blow-hole at the inflection point. There
are physical limitations to the size of the weld radius depending upon the welding system. Figure
9 on page 11 illustrates a wheelhouse design for Ford-Cologne that has been investigated at
Tailor Steel of Genk, Belgium.

Circular TWB applications are found in shock towers, such as those at Renault (Ref. 11). The
complexity of circular TWBs is much less than that of non-defined curves because of edge fit up,
where a circular disc can be inserted into a round hole, and tooling for welding in a circular path
as can be performed using a rotary table.

9
 Non-linear Weld Application
Floor Panel (double attached)

Figure 7- First known non-linear production TWB - produced by Laser Welding

International, formerly Prototech Laser.
0.98 m

1.3 m

t = 0.7mm
t = 2.0mm
t = 2.2mm

Figure 8 - Analysis of different door designs (Thyssen Krupp Stahl).

10
 0.75mm

1.5mm

0.75mm

Figure 9 – Curvilinear wheelhouse developmental application.

3.1.7 PATCH

The concept of a patch TWB is not new and several applications are in production. A patch TWB
overlays one blank of material on top of another blank to add strength where it is needed. The
two blanks are joined, usually by spot welds, before forming (Figure 10 on page 12). TWB
welding constraints such as edge condition for butt welding and designing blanks for linear
welding systems are eliminated. Consequently, patch TWB designs have greater flexibility and
generally less cost than the conventional TWB counterpart. Major questions regarding patch
TWBs concern structural performance, fatigue, and formability. Evaluating these properties may
be more difficult than with conventional welded blanks, where there may be multiple steel blanks,
but each blank can be modeled somewhat independently, aside from the weld line. With the
patch blank, the performance of multiple layered blanks must be considered and their
performance will be affected by the joining design, whether spot welds, adhesives, or another
technology. One advantage of patch blanks over conventional, multi-piece assemblies is the
superior fit-up that is achieved. Since the multiple pieces are formed in the same die, the fit-up
between the reinforcements and larger blank is excellent. This superior fit-up can simplify respot
welding and improve the structural performance and quality over a non-TWB.

There are two important design considerations for patch tailor welded blanks, which are illustrated
in Figure 10 on page 12. The reinforcement patches on both blanks do not extend to the edge of
the larger blank and therefore remain clear of the draw die binder. This simplifies binder design
and forming complexity. A second observation is that each patch is joined using either two or
three spot welds and the location of these spot welds is on the “flat” area of the finished part.
Minimizing the spot welds will allow for material flow on the curved surfaces. Additional spot
welds, or respot welds can be added later in the assembly process, as needed.

11
 Floor pan bar. Patch-type tailor welded
blank with two patches, each with two
spot welds. This double-attached tailor
welded blank is shown before and after
forming.

Longitudinal rail. Patch-type tailor

welded blank with one patch
reinforcement (fish shape). The patch
has two locating holes (one at top and
one at the bottom), and three spot
welds. Additional spot welds are added
after forming.

Figure 10 – Two examples of patch-type tailor welded blanks.

Figure 11 on page 13 illustrates a door inner example for a conventional design, a traditional
TWB with a laser weld design, and a patch design. The patch design in this illustration results in
lower overall door mass and lower cost.

12
 subject: pa tch blanks v s. co nv. & la se r
opti on - spot we lded
1.7
0 .66 1.7 0.66
0.66

1.7

co nve ntiona l 2-pc la se r w elde d 3-pc p a tch blank

doo r inn er panel p c co s t weig h t # i n v( mil) p c co s t wei g h t # in v(m il) p c c o s t we ig h t # in v (m il)

ra w mate rial we ight 28 .52 41.8 1 37.85
m ateri al c ost $9.10 $13.68 $12 .32
b lank die inves tment 0.07 0.15 0 .07
b lanking $0.69 $1.05 $0 .96
l aser we ldi ng (b lank ) $0.00 $3.49 $0 .00
s pot wel ding / in ve st (bl ank ) $0.00 $0.00 $1 .48 0.1
finis h wei ght 12 .15 17.0 8 13.76

hing e reinforce m ent

ra w mate rial we ight 9 .32
m ateri al c ost $3.08 $0.00 $0 .00
b lank die inves tment 0.05
b lanking $0.41 $0.00 $0 .00
s tamp ing $1.71 0.45 $0.00 $0 .00
finis h wei ght 4 .75
a ssembly cos ts / pick-up welds $0.74 0.5 $0.00 $0 .74 0.2

to tal $ 15.73 1 6.9 1.07 $18.22 17.0 8 0.15 $15 .50 13.76 0 .27

i nvest / 4000 00 units / 5ye ars $0.54 $0.08 $0 .14

$ 16.27 $18.30 $15 .64
w eight im provem ent ov er conv entiona l 1 8.6%
w eight im provem ent ov er laser welded 1 9.4%
cost im provem ent ov er conv entional $0.63
cost im provem ent ov er laser we lded $2.66

Figure 11 – Patch TWB comparison for door inner.

3.1.8 TUBES

There are several factors that contribute to the increasing interest in tailor welded tubes (TWTs).
In general, tubes for body-in-white applications are hydroformed. Currently available tubes have
limitations regarding their diameter to wall thickness ratio and relatively low formability due to
conventional tube production processes and the resulting weld quality. One tube-welding
supplier, Soudronic, indicates that they can weld thin-walled tubes using their Soutube laser
welding process with a D/t ratio (tube diameter to wall thickness) of 65 - 200, where standard tube
ratios would be in the order of 17 - 38.

Tube shapes and tailor welded tubes can come in a variety of shapes, and can be welded with
mash or laser. Figure 12 on page 14 shows four tube options:
• Cylindrical tubes,
• Tailor tubes (varied wall thickness),
• Oval tubes, and
• Conical tubes

13
 Figure 12 – Four tube shapes: cylindrical, tailor shape, oval, and conical.

Tailor welded tube applications are feasible wherever hydroformed tubular applications are
considered. As in flat applications, the TWTs allow for added optimization of material use.
Examples of possible tailor welded tubes include:
• Exhaust manifolds;
• A-pillar;
• Engine compartment rails;
• Light truck side rails,
• Rollbars, and
• Side rails.

Several companies are researching TWTs. Soudronic and AWS have welded multi-gauge tubes
to produce hydro-formed TWT parts. The production technology is available, as in the Soutube
process by Soudronic, to produce cylindrical and conical TWTs, but a production application has
yet to be determined. Soudronic has also experimented using filler wire and CO2 laser. They
have welded aluminum tubes with and without filler wire with success. ATB company of Holland
and Corus in the UK have purchased Soutube welders (Ref. 11). Corus indicates that the wall
thickness on the TWTs can vary from 0.6 mm to 3.0 mm. ATB believes that design integration to
incorporate hydro-formed tubes into conventional auto bodies will be the limiting factor controlling
demand. Thyssen Krupp Stahl also indicated plans to produce TWTs in the near future.

Another type of TWT uses a sleeve in the area where reinforcement is needed. This approach is
analogous to the patch type TWB where butt welding two separate pieces of material is avoided
and the material is simply overlapped and attached. A second type of TWT uses an expandable
foam material that can be inserted into the tube. Several companies are developing expandable
form technologies, including the Fraunhofer Institute.

14
 Figure 13 – Tailor welded tubes: constant OD, constant ID, and “sleeve”.

The greatest interest in welded tubes is for cylindrical or conical tubes, with conical of greatest
interest, with small diameter to thickness ratios. Much less interest has been shown for tailor
welded tubes (Ref. 11) in Europe. Thyssen believes that the first TWB tubes will be in production
in three to four years and that the greatest challenges to the auto manufacturers will be
addressing the forming and joining challenges (Also Ref. 11).

Soudronic Concept Soutube Welding

Figure 14 - Soudronic Soutube welding videos.

15
 Figure 15 - Soudronic Soutube welding unit for tailor tubes.

2.1.6 HIGH STRENGTH STEEL

There is a high level of interest in using high strength steel (HSS) in TWBs for further mass
reduction and structural improvements. Two concerns limiting the use of HSS is the formability in
conjunction with the weld bead and other materials in the TWB and the weldability of the steel.
Typical applications include the B-pillar, as the Volvo S-80 uses DP600, and longitudinal rails, as
the Focus uses 340 Mpa. Several auto companies are investigating use of high strength steel on
the B-Pillar of the body side but are concerned with formability. Mazda indicated that they plan a
body side with high strength steel, and Toyota has several body sides that incorporate HSS.
Japanese body sides, however, tend to have less depth of draw than North American designs.

Filler wire may be used to increase the formability of the weld when welding with laser. The Ford
Research Center and Soudronic believe that mash welding may be a better method for welding
HSS because of improved fatigue resulting from the overlapped joints (Ref. 11).

The Ford Research Center in Aachen, Germany is developing design guidelines for the use of
HSS in TWBs. They anticipate future research on HSS TWBs that will address usage of steel
grades, weld line placement, and springback prediction (Ref. 11).

2.2 NORTH AMERICAN APPLICATIONS

Future estimates for TWB demand vary according to source, but all show continued linear growth over
the next several years. Figure 16 on page 17 shows two projections, one by TWB (Ref. 81) and one by
AWS (Ref. 62). Another source (Ref. 4) estimated the TWB market value in 1999 at $100 million,
translating into an average TWB cost of a $4.25 per piece, excluding steel cost. The estimated tonnage
sold in 1999 was 315,000 tons, which translates into approximately 27 pounds per TWB.

16
 Projected Tailored Blank Demand
for North America
100

Annual Volume
(million pcs.)
80
60
40
20
0
1999 2000 2001 2002 2003 2004 2005

TWB (1999) AWS (2000)

Figure 16 - Projected tailor welded blank demand for North America – based on two sources

General Motors and DaimlerChrysler lead in the number of TWB applications in North America, with Ford
a distant third (Ref. 81). GM has been one of the world leaders in body side applications, including
DeVille, Seville, LeSabre, Aurora, Bonneville, Silverado/Sierra regular, Silverado/Sierra extended, Tahoe,
Tahoe XL, Suburban, and Blazer (Ref. 95). North American body side TWBs, including GM, have tended
to apply more to body side panels and have resulted in fairly long total weld lengths (Figure 17, below).
GM also has a number of door inner panels, including Impala front/rear, Monte Carlo, and DeVille
front/rear. In 2000, GM had an estimated 65 TWB applications as follows (Ref. 96):
• 24 door inners
• 18 body side frames
• 23 other

DaimlerChrysler has slightly fewer TWBs at a 50, with a large percentage of door inners, body side
inners, liftgate inners, rails and reinforcements. Two DaimlerChrysler products, the Jeep Grand Cherokee
and the Durango had the most single line applications in North America with eleven and nine respectively
(Ref. 4).

B ig-3 B ody S ide

• T otal length of w eld lines (incl. cut outs) , about 4867m m .

1.0 bare 1.4 bare

1425 1925

1517
0.8 H D G 1.0 H D G

Figure 17 - North American body side with over 4.8 meters of weld.

17
The greatest level of interest in non-linear (curvilinear) TWBs exists in North America. No one in Japan
expressed any significant interest and there is only moderate interest in Europe, probably for door inners.
GM has shown the most interest for a variety applications, while DaimlerChrysler has shown little interest
beyond single and multi-straight line TWB applications for the near future.

Production applications for tailor welded blanks are beginning to reach projections. One early study
identified approximately twenty-two practical applications on a car body. In 1998, ULSAB identified fifteen
cost-effective applications for a high-volume vehicle, shown in Figure 18 below:
• Rail front inner (left and right)
• Rail front outer (left and right)
• Rocker inner (left and right)
• Rail rear inner (left and right)
• Rail rear outer (left and right)
• Wheelhouse outer (left and right)
• Body side outer (left and right)
• Panel skirt

Figure 18 - ULSAB tailor welded blank applications.

Figure 19 on page 19 charts the estimated worldwide TWB demand, in parts produced.

18
 180
160

Millions of Parts per Year

140
120
100
80
60
40
20
-
1998 1999 2000 2001 2002 2003 2004

Data provided by Soudronic

Figure 19 - Estimated worldwide TWB demand (in parts produced).

2.3 EUROPEAN APPLICATIONS

The leading applications for TWBs in Europe are rails and pillars, most with a single weld. In most cases,
these applications are multi-gauge blanks, sometimes with high strength steel, with the objectives of
mass reduction and structural improvement. Door inners are the single largest application, followed by
underbody components. A distribution of European applications, provided by Thyssen Krupp Stahl, is
shown in Figure 20 below.

Figure 20 – Distribution of European applications by type and quantity.

19
Volkswagen is one of the world’s largest uses of TWBs, with the Golf having approximately 23
applications over 3 models, and the Golf 4 alone having 16 applications (Ref. 11). Two of the Golf’s rear
rails have one side welded with mash welding while the other is laser welded because of production
availability of the equipment. The major objective of most of the Golf’s applications is part integration, for
cost reduction, and crash behavior.

Tailor Steel, Genk, indicated that Ford-Cologne is interested in a non-linear wheelhouse application (Ref.
11), shown in Figure 9 on page 11. The Ford Mondeo is expected to have six TWBs.

The Peugeot 607 sedan has a TWB with multiple straight line welds and a design that is similar to many
of Toyota’s body sides. This design makes use of several short welds along the A and B pillar using
developed blanks, as shown in Figure 21, below. Shallow draw body sides are compatible with this
design.

Figure 21 – Peugeot body side with “short” welds.

BMW has several door applications with designs that differ from those seen in North America. The BMW
3-series makes use of a multi-straight line welded blank on a double-attached door inner. The multi-
straight line weld is made for welding efficiency since the finished door inner only has a single weld line
on it. This blank is welded at Tailor Steel in Belgium and is shown in Figure 22 on page 21. The
objective of this application is structural, that is, to increase the stiffness near the door locking area will
reduce high-speed wind noise. BMW also has front and rear TWB door inner panels on other vehicle
models. The main purpose cited on these applications is for structural improvements, or increased
rigidity, and mass reduction.

20
 Volume: 62,000
Objective: weight reduction, structural improvement
Gauges: 1.8mm/0.8mm
Weld: 1300mm

Figure 22 - BMW 3-series door inner.

Rover also has several TWB applications, indicating that they have front and rear door TWBs on the
Rover 75 for cost reduction. They also have a rear wheelarch, or wheelhouse inner, and a side rail on the
same model. The objectives of the latter applications are cost reduction and structural, respectively. The
Rover Mini (R50) will have tailor welded body sides made from four blanks and three weld lines. The
Mini’s body sides are justified based on structural and cost improvements.

Renault is becoming an aggressive user of TWBs. Renault has body sides on 3 models in production
(Ref. 11). They also have one of the few non-linear TWB applications with a circular shock tower TWB
used on the Kango mini van. The Renault Laguna, produced at the Sandouville plant, has 13 TWB
applications justified mainly through crash management and mass reduction objectives. The 13 Laguna
applications are:
• Body sides (2)
• Lower compartment rails (2)
• Upper compartment rails (2)
• Front and rear doors (4)
• Floor pan reinforcements (2)
• Plenum (1)

Audi, Volvo, BMW and Renault all make significant use of high strength steels in TWB applications. High
strength steel applications are seen in rails, reinforcements and cross members. In general, Europe has
few TWB side rings in production or planned; however one is currently designed with bake hardenable
steel for production.

21
2.4 JAPANESE APPLICATIONS

Tailor welded blanks in the Asian market are spread across Toyota, Nissan, Honda, Mazda, Daewoo, and
Hyundai, with other companies using them to a lesser extent. Toyota is the most dominate user of TWBs
in Asia with over 70 applications in production, and the most aggressive with several multi-straight line
weld body sides. Most of the applications seen in Japan are justified for economic reasons due to
material savings or tooling cost reduction through the integration of parts. Typical Toyota applications
are:
• Engine rails (upper and lower),
• Door inners,
• Sun roof (welded in the four corners to save the material in the center),
• Pillars (especially B-pillars), and
• Inner body sides.

At one time Toyota produced body side outers, but found the marginal savings insufficient. Greater
savings were found by welding the body side inner. On the body side inner, greater gauge differences
can be welded, thereby eliminating more parts, and there is minimal concern over laser welding exposed
material. The (Japan) domestic Camry is now the only body side TWB with exposed welds, and these
are on a class B surface. Figure 23 on page 23 contrasts the body side inner on the Crown with the body
side outer on the Camry. The body side outer blanks are all made from 0.8 mm steel of the same grade
but with different coatings. The body side inner has different gauges, 1.0 mm, 1.2 mm, and 1.6 mm, with
different coatings, and different steel grades, from 390 Mpa to 440 Mpa. The total length of the four body
side inner welds is only 780mm and the total for the body side outer is 1.425 m. The relatively low
welding cost and high steel differentiation on the body side inner illustrates the greater savings potential
on the inner panel.

In Georgetown, Kentucky, Toyota makes TWBs for in-house use, producing:

• Camry front door inners
• Avalon body side inner
• Sienna front door inners
• Sienna front side member inner

The door inners require the capacity of two of their turntable weld systems, and a third system is used for
the other applications. The Avalon body side inner is a typical shallow draw design with three welds: B-
pillar to roof, roof to upper A-pillar, and upper A-pillar to lower A-pillar, with no rocker panel). The total
weld length is about 1.050 m for all three welds.

Toyota has indicated very little interest in developing non-linear, or curvilinear weld TWBs. They
generally believe that there are sufficient opportunities with multi-straight line welds still to be exploited,
and these offer fewer complications and nearly the same benefits of curved welds (Ref. 10). Toyota is
interested in a rear door application that has two straight line welds, connected and perpendicular to each
other, because there is no mirror reinforcement.

22
 Figure 23 – The Toyota Camry body side outer (top) and the Toyota Crown body side inner
(bottom).

Nissan is perhaps second in Asia in TWB volume to Toyota with roughly fifteen applications. They
currently have no door inners in production because of concern over weld quality for these relatively long
welds. A door application has been planned for a headerless door to improve structure on a small
volume vehicle. Applications include:
• A double-attached center pillar,
• A double-attached roof rail,
• A body side outer panel with two welds connecting the rocker panel to the A and B pillars as
shown in Figure 24 on page 24, and
• A body side inner panel using high strength steel in the B-pillar, shown in Figure 25 on page 24.

23
 Nissan Body Side (Outer)
• 240,000 annual volume vehicles (480,000 body sides).
• Total weld length: 975mm.
• Same gauge blanks (0.8mm).
• Steel coated on bottom, bare on top.
• Design objective: cost reduction.

SPC 0.8 mm

525mm 450mm

Dura 0.8 mm

Figure 24 – Nissan TWB body side (1998 production start).

Nissan Body Side (Inner)

• 66,000 annual volume vehicles (132,000 body sides).
• Total weld length: 760mm.
• Multi-gauge blanks (1.0mm to 1.6mm).
• High strength steel in B-pillar.
• Design objective: mass reduction.

440MPa
1.6mm
215mm

240mm
SPC 440MPa
1.4mm 1.2mm

305mm
440MPa
1.0mm

Figure 25 – Nissan body side outer panel with high strength steel.

24
Nissan justifies most applications based on cost savings. Nissan and Toyota body sides tend to be
shallow drawn panels with overall short weld lengths. Mass savings are second in importance, to cost.
Nissan will continue to look at door applications in the future.

Mazda has two TWB applications, a lower B-pillar reinforcement and a cowl piece. The volumes are low
and the parts are welded in-house with a CO2 laser system. One of the applications recycles two pieces
of offal by welding them together into a larger blank, and the weld line is stamped out of the final part.
The main objective at Mazda is cost reduction and the desire to gain knowledge of the technology. In the
future, Mazda would like to implement door inners and a body side TWB. They expect the body side to
use HSS. Mazda has found that laser welded blanks have better corrosion resistance than mash and
that laser welded blanks have better formability than mash because of the HAZ (Ref. 10).

25
 3.1.9 WELD PROCESSING TECHNOLOGIES

3.2 WELDING POWER SOURCE

3.2.1 INTRODUCTION

The development of different welding technologies is progressing rapidly and the relative
advantages and disadvantages of these technologies change quickly. The formability tradeoffs
between mash and laser welding are not conclusive. Mash welding has a lower overall micro-
hardness, but over a wider area, or heat affected zone (HAZ). One OEM study shows that laser
blanks have greater tensile elongation parallel to the weld than mash welds. In contrast,
however, the study showed that the laser weld failed with a lower bending fatigue close to the
weld line.

The performance of these technologies is also dependent upon the weld automation system
incorporated. The following table subjectively compares perceived performance tradeoffs of the
major tailor welded blank welding technologies. Although non-vacuum electron beam blanks
have been mass-produced in the past, no known system is in operation today. The other
technologies are all in production. Induction is in production at Volvo in Sweden, and the other
technologies of mash seam, CO-2 laser, and YAG-laser are in production in multiple locations
throughout the world.

Electron
Induction Mash Seam CO-2 Laser YAG-Laser
Beam

Rework Weld no needed cold rolling no no

in in
Coated/Uncoated possible possible in production
production production
in
Curve Welds possible no no high favorable
production
in
High/Low Strength possible difficult possible high favorable
production
Changing in
possible no no high favorable
Thicknesses production
in
T-Weld Lines possible no no high favorable
production
Industrial
difficult good good good possible
Integration

Forming behavior very good difficult good good very good

high
Edge Preparation precise easy medium precise
precision

Table 1 – Comparative tradeoffs between welding technologies.

26
Technological advancements in welding technologies and systems are being made in several
areas, with several key developments are in the following areas:
• Non-linear welding capability, both multiple-linear welds and curvilinear welds;
• Elimination of precision shear requirements for welding. Edge fit-up is being addressed
more precise blank dies and increased welding robustness, such as welding with dual
spot beams;
• In-line quality checks to assure that no defective blanks are shipped to the customer.
100% inspection systems are becoming more accurate at identifying suspect blanks;
• General process improvements, including minimizing downtime between load/unload part
cycles, welding speed approaching 10 meters/min., reduction in scrap rates to under 1%
in many applications, and reduced material handling through lower inventories, steel pin
pallets, etc.

3.1.2 CO2 AND Nd:YAG

CO2 laser is still the dominant welding technology worldwide. Thyssen estimates that
approximately three-quarters of the total North American market uses CO2 for blank welding, with
Yag and mash making up the remaining 25% (Ref. 71).

There are numerous different TWB manufacturing systems, but over 90% employ either CO2 or
Yag laser energy sources. The CO2 laser beam can be focused more precisely than a Yag
beam, a condition that offers advantages when the blank edge condition has minimal gap. The
more tightly focused beam can weld faster because more of the beam is concentrated at the
edge. When the edge condition is poorer, than the more dispersed Yag beam, with its “top hat”
shape, simpler delivery mechanism and twin-spot capability may have advantages, although
there is also current research on a twin-spot CO2 laser as well. There is interest by weld system
suppliers to consider adopting Yag over CO2 laser for more complex blank applications because
of edge fit-up concerns. Thyssen Krupp Stahl has installed Nd:YAG on two of their welders (Ref.
11) and cited the advantages in gap tolerance and non-linear welding flexibility. Soudronic and
VIL have also investigated using Nd:YAG in lieu of CO2 laser.

Another reason for the growing appeal of Nd:YAG over CO2 laser is cost. Both laser
technologies have seen reductions in their cost per kilowatt of power over the past several years.
Nd:YAG, however, has decreased its cost/kw faster than CO2, while seeing significant increases
in the available power output. A lagging concern over Nd:YAG is still the operating cost. In
particular, the replacement cost of lamps is high at about $300 apiece and the operating life is
highly variable, ranging from 300 to 800 hours. Twelve lamps may be required for replacement
on a 4kw Nd:YAG laser.

Soudronic has conducted controlled experiments to identify the critical laser welding process
variables for CO2 lasers, and have prioritized the important variables into three groups: critical,
delicate, and non-critical as shown in Table 2 below.

Critical Delicate Non-Critical

• Focus diameter • Focus position • Weld speed
• Edge contamination • Shield gas tube position • Laser power
• Edge straightness • Shield gas flow rate
• Edge quality

Table 2 – Process control variables for CO2 laser welding (Soudronic results)

27
There are several resistance mash welding systems, mostly supplied by Soudronic. This
technology has been displaced by laser systems because of minimal perceived cost advantages,
weld geometry disadvantages (weld-seam thickness), and concern over corrosion along the weld
bead. Toyota, Nissan and DaimlerChrysler have found several applications where mash welding
offered lower costs, suggesting that demand for mash welding may be decreasing, but is not
likely to go away completely. The most common concern expressed over mash welding is the
challenge in welding galvanized steels. Certain galvanized coatings, such as galvanneal, have
been welded in volume without significant difficulty. Thyssen Krupp, possibly the largest producer
of mash welded blanks, had plans to phase out mash in favor of laser welded blanks by calendar
year-end 2000 (Ref. 62).

3.1.3 PLASMA AUGMENTED LASER WELDING (PALW)

Plasma augmented laser welding is a welding methodology that supplements the laser heat
source with one or two plasma jet heat source(s). Combined, the laser and plasma heat source
produce a weld with a wider heat affected zone, which produces a more gradual weld transition
from thicker to thinner gauge steels. This wider weld allows for a more forgiving gap tolerance,
potentially eliminating the need for precision edge shearing or die cut edges. The increased
energy also allows for faster weld speeds. Several companies have been experimenting with
PALW for TWBs including BMW (Ref. 31). Liburdi Pulsweld (see appendix) has been conducting
in-house research for TWB applications including aluminum welded blanks. Toyota has a
production welded part today using plasma welding, supplied by Pacific Industry, on a center
pillar (Ref. 10).

3.1.4 INDUCTION AND NON-VACUUM ELECTRON BEAM

Volvo continues to use induction welding, but the comparative success of this method versus
laser is not well known. ABB and Kuka may be marketing this technology outside of Volvo,
perhaps with a licensing agreement with Volvo; however, there has been low interest due
primarily to the weld geometry (Ref. 11).

Non-vacuum electron beam welding still has the potential to produce welded blanks. An electron
beam equipment supplier, PTR of Enfield, CT, has conducted laboratory welds on both steel and
aluminum. Thyssen Krupp Stahl indicated that they have conducted electron beam studies, and
they believe that the technology has potential in the future. This technology was originally in
production in the 1980s on heavy steel TWB components.

3.1.5 MASH WELDING

Mash welded blanks are joined with a technology that is more familiar to the auto companies than
is laser welding. Resistance mash welding is a contact welding process that uses roller wheels
and electrical current and welds on an overlapped sheet steel edge. This technology is not as
new as butt-edge laser welding and has been widely applied to many applications including cans
for the food industry and steel gas tanks for automobiles. Soudronic AG in Neftenbach,
Switzerland, is a world leader in supplying this technology. One of the recognized advantages of
mash welding is the fact that this resistance welding technology is familiar to automotive
environments and the infrastructure to operate and maintain this equipment is fairly well
established. A counter argument voiced by several welded-blank suppliers is, while they
recognize the higher initial investment into learning laser welding technology, the long-term
benefit is that laser technology has fewer moving parts and requires less ongoing maintenance.

28
The pros and cons between mash and laser welded blanks have been discussed for years,
particularly in the early 1990s when it was not clear which technology would win favor. Most of
the early disadvantages of laser welding have been overcome. Several of these disadvantages
included higher operating complexity, higher investment costs, lower welding power and slow
welding, edge preparation complexity, and formability concerns because of the harder weld. The
disadvantages of mash welding were the number of moving parts that required maintenance,
welding of coated materials, possible corrosion due to coating removal during weld, wider heat
affected zone (HAZ), and increased weld bead thickness due to the overlapped edge. As both
technologies have evolved, many of these issues for each have been resolved. An important
issue remains relative to formability differences, which suggests that the harder but narrower HAZ
from laser welds in many applications is advantageous over the mash weld. Mash welding is still
more forgiving in edge fit-up than laser so this can be an advantage in some cases. The cost and
power relationship between mash and laser has been eliminated. As blank applications trend
toward more complex, multi-weld and even curvilinear welds, the more flexible laser can have an
advantage with the proper tooling. In summary, the advantages of laser welding, on average,
have outweighed the advantages of mash welding, and laser has become the dominant
technology. There are still, however, applications where mash has advantages, and a mix of
these technologies is likely for some time.

Weld Comparison

lide: 37

Figure 26 - Comparison of Four Welding Methods.

29
3.2 DUAL SPOT WELDING (MULTI-SPOT)

Several companies have developed multi-spot welding, usually dual spot, which has been shown to be
practical with both Nd:YAG and CO2 laser. The main advantage of dual spot welding is that more power
is distributed wider along the path, thus allowing more steel to fill the gap. The result is a slower welding
speed but a broader HAZ and greater likelihood of an acceptable weld. Another advantage of dual spot is
that when a gap is present, energy is not lost through the gap, which can occur if the weld beam is too
narrowly focused.

Tailor Steel indicated that they are investigating dual spot welding for non-linear, or curvilinear welds
because of the difficulty of achieving close edge fit-up. They are currently using dual spot even on linear
welds because of its robustness to edge conditions. One challenge with curvilinear welds, though, is that
the two spots do not travel at the same speed around a radius. Since the inner spot travels slower, the
nature of the weld changes. Both process tracking software and associated hardware are under
development for this problem (Ref. 11).

3.3 EDGE & BLANK PREPARATION

Good edge conditions, or the lack of burrs and gaps between the blanks, is a key to achieving quality
welds and maximizing weld speed. Poor edge conditions require special provisions such as close
process control monitoring, twin-spot laser to melt material into the gap, and slower weld speeds. Most
companies and welding systems rely on precise blank dies for edge preparation. In Asia, Toyota, Nissan
and Mazda have all developed precise blank die edge technology and require that product design limit
weld length based upon this capability. At Nissan, their blank die uses a closer shear edge clearance
and special guides (Ref. 40). Toyota indicated that they require a die clearance of less than or equal to
0.05 mm for blank edges. This requirement results in doubling blank die maintenance. Thyssen Krupp
Stahl indicated that 98% of the blanks that they weld utilize blanking dies as a means of producing a
weld-able edge condition (Ref. 11). Thyssen estimates that about 85% of the blanks welded in Europe
rely on blank dies for edge preparation.

An oscillating shear is not adequate in most cases to produce weldable edges. Thyssen Krupp Stahl and
Medina Blanking both indicated that edge condition, particularly straightness, couldn’t be maintained with
an oscillating shear, even for edges to be mash welded. However, a fixed shear may produce an
acceptable edge up to some length.

Tailor Steel in Belgium uses a “slap die” to make blanks which produces an acceptable welding edge for
Soudronic and Toyota systems. This die requires maintenance every 700,000 hits. Flattening rollers are
required on the blanker with 22 roller sets. Blank flatness was cited as a major problem at the Tailor
Steel of America facility during their early trials.

The decision to use a blank die versus a precision shear is blank shape and volume dependent. Thyssen
Krupp Stahl suggests that when the annual volume of a contoured blank exceeds 200,000 units per year,
the volume warrants a blank die because of the material savings.

The Soudronic SOUKA technology cold mashes the edges together before laser welding. Blanks are butt
welded together and the roller mash process is reportedly, according to ATB, capable of tolerating gaps
up to 0.3 mm (Ref. 11).

30
 ®
Figure 27 – Soudronic SOUKA process for edge preparation.

Toyota and Renault have used a method wherein oversize blanks are crowned and then clamped down
to exert pressure on the edge. Renault does this with a circular shock tower disc inserted into a blanked
hole (Ref. 11). Toyota accomplishes this with blanked pieces, developed blanks produced from dies, in
their assembly jig on body sides.

Another strategy developed by Thyssen Krupp Stahl is the “sheet-in-sheet" method that can be used on
circular shock tower applications. This method places both sheets on top of one another and punches
the desired shape, a circular disc in this case, so that the top thicker gauge sheet displaces the same
shape out of the bottom piece, leaving a close edge fit-up around the part. The sheared edge condition is
sufficient to produce a good weld (Ref. 11).

Backup
Flame Size up Pad Pow er Up

Upper
Pad
Blade
Moving Increasing
Backup Side Force
Blank
Frame

Lower Blade Changing Guide Post

Special Blade & Blade Clearance
Cutting Condition Added Guide Unit

Figure 28 – Special blank die design for precise edge condition used at Nissan.

31
3.4 WELDING PARAMETERS

Virtually all laser welding system suppliers suggest the use of a shielding gas during the welding process,
with various combinations of helium and nitrogen typically used. AWS indicated that a shielding gas is
not required with Nd:YAG welding (Ref. 62), but companies experienced with Nd:YAG recommend it.

Clamping technology varies by system design, but predominant methods include hydraulic and magnetic
clamps, sometimes with air, or vacuum, assistance.

Several welding system employ seam tracking devices with adaptive control for welding. These systems
typically use a laser beam to track and guide the weld path with the table or laser making small lateral
adjustments, within a few millimeters. Seam tracking systems, like the Soudronic Souvis 1, can often test
several criteria, including lateral edge position, excessive gap, mismatch, edge defects, and blank
position. Not all welding systems rely on seam tracking, as Prototech Laser welds a semi-circular arc
without tracking.

Renault Automation indicated that they use seam tracking software from MVS, a Canadian company
(Ref. 11). Their concern, however, is that commercially available software is adequate for tracking
straight line paths, but software for non-linear paths is not yet commercially available.

Weld systems that rely on seam tracking, as opposed to having rigidly programmed weld paths, may have
a limitation on welding radii. One supplier indicated that a 100 mm radius may be the lower limit when
seam tracking is used, as opposed to a 40-50 mm radius for non-seam tracking systems.
1
3.5 TAILOR WELDED BLANK FORMABILITY
3.5.1 INTRODUCTION
Press formability of TWBs is related to the relative material strengths and the ductility of the weld.
The pattern of deformation has a strong impact on overall formability, making general rules-of-
thumb difficult to develop. The deformation pattern, including weld line displacement, is governed
largely by material selection, weld line placement or orientation, and the forming forces. Both
laser and mash welds reduce ductility of parent mild steels by 50% to 75% for parallel strains.
Generally, the weld properties themselves have much less affect on deformation behavior.

TWB welds are equal to or greater in strength than the parent material when made to generally
acceptable standards (Please see A/SP TWB Acceptance Guidelines). Generally, it was found
that laser welds are stronger and mash welds are equal in strength to the stronger of the two
blank materials. Weld line formability is important for at least two reasons:
• Rupture during forming;
• Transverse weld line movements affect die design and wear, and possibly part
designs.

The designer must consider these factors in designing the TWB, in conjunction with the part
performance objectives. Weld line movement can be controlled using draw beads or
differentiated blank holding. Differentiated blank holding technology is not in wide use because of
added die cost and forming complexity. The reduced formability in the weld region versus that of
the un-welded parent material can be managed in several ways:
• Weld line placement: amount of strain and its orientation to major strain;
• Selecting a forming method: stretch, draw, stretch flange;
• Weld profile: peak hardness versus width of weld, controllable in the welding process;
• Material selection which affects weldability and the weld profile.

1
A significant contribution of information for this section was obtained from references 87 and 103.

32
Different forming methods affect TWB formability. Stretch forming results in the lowest formability
when the weld is parallel to the major strain axis because of the limited weld bead ductility. When
the major strain is perpendicular to the weld, the weaker material becomes the limiting factor.
The TWB weld has minimal impact on deep drawing. Stretch flange forming has a 25% to 30%
reduction in formability.

3.5.2 FORMABILITY TESTING: PARALLEL AND TRANSVERSE MAJOR STRAIN

Formability testing of the welded blank seam is recognized as an effective predictor for blank
formability. The most common testing methods are tensile tests, various LDH tests with different
punch geometries, Olsen Cup, and the OSU formability test. These physical tests showed
significant sensitivity to punch and specimen shape. Finite element analyses also provide some
meaningful results, but to a limited mix of weld profile and material types.

Experimental results showed that weld failure in a laser welded blank depended on the weld line
orientation relative to the major strain and the relative strength of the two materials. Blank failure
occurred parallel to the weld in the weaker material when the major strain was perpendicular to
the weld orientation. The size of the welded blank or test sample affected how close the failure
was to the weld. Wider material samples showed the failure closer to the weld.

Blank failure occurred across the weld when the major strain was parallel to the weld orientation,
as shown in Figure 29 below. For optimum performance, the weld bead should be parallel to the
major strain axis to prevent the failure in the weaker material.

stron g w ea k
M a jo r S tra in

w e ld fa ilu re

stron g

M ajo r S tra in

w ea k

Figure 29 - Failure patterns for tailor welded blanks.

3.5.3 WELDING AND WELD PROFILE

Several opinions exist regarding the importance of peak weld hardness versus the weld width.
Greater hardness reduces the ductility and therefore reduces the formability of the weld.
Increased welding speeds generally require higher energy intensity at the weld which increases
peak hardness. In the case of laser welded blanks, this may require more precise edge fit-up so

33
 that the energy beam can be more narrowly focused at the weld seam. Higher intensity laser
weld seams generally produce narrower weld widths; however, some studies have shown that the
cross-sectional area of increased hardness at the weld seam is more important than peak
hardness. The formability appears to be related to a function of the weld hardness divided by the
area of the HAZ (H/HAZ). Overall formability is then critically important to two offsetting factors:
• Reduced weld seam width, and
• Reduced peak weld hardness.

Generally it has been found that mash welds are more ductile than laser welds because of their
lower peak hardness. If the mash weld has to be cold planished to reduce the weld seam
thickness, then the hardness can be equal to or greater than the laser weld. Warm planishing
has minimal effect on mash seam ductility.

The parent material significantly affects weld ductility. Low alloy, or mild, and interstitial-free
steels can normally be welded at high speeds, produce narrower weld widths, and have higher
formability than other steels. High strength steel tends to produce harder welds, which may
require slower welding speeds in order maintain sufficient formability.

3.6 DEFECTS AND DEFECT DETECTION

3.6.1 WELD QUALITY

The most common method of direct testing of weld quality is a destructive test, such as the
Erichsen cup test, and sometimes a peel test. Toyota reserves one blank per pallet for
destructive testing, and tests the weld every several inches (Ref. 10). Renault also uses the
Erichsen test, but tests welded blanks once per shift (Ref. 11). Tailor Steel of America in Holt, MI
also conducts the Erichsen test on one blank per pallet. Many producers indicate that they are
able to achieve defect rates of less than 2% once steady state is reached (Ref. 11). Tailor Steel
of America indicated that they experienced 3%, but on fairly complex body sides for GM
containing three long welds.

Several on-line weld-monitoring technologies are in various stages of readiness today (Ref. 81).
Two developmental systems involve video keyhole analysis and laser ultrasonic. The most
commonly use systems today include:
• Weld plasma monitoring;
• Structured light profilometry;
• Electro-magnetic acoustic transducer (EMAT);
• Pinhole detection.

3.6.2 WELD GEOMETRY

The weld profile is a strong indicator of an acceptable weld. Several welding systems incorporate
weld profile tracking within a few inches after the welding process and send a signal to “reject” the
part if the profile is outside an established tolerance. A laser beam is used in conjunction with a
CCD camera. Typical test criteria include weld seam concavity, seam convexity, mismatch, bead
width, weld penetration, or lack of, and lateral bead position. These systems have been observed
on Soudronic (Souvis 2), TWB, Toyota, and other welding systems.

In practice, the weld quality monitoring systems have not proven to be consistently and uniformly
adequate for all welding operations. Companies wishing not to allow defects to be shipped either
set the sensitivity of the monitoring software to identify a large percentage of false positive
readings that are not actual defects or supplement the process with operator inspection.
Operators in some cases are used to visually inspect welds 100% of the time. One supplier

34
indicated that approximately 2% to 3% of the welded blanks were defective, and that 0.15% of the
defects were actually shipped.

Plasma Monitor
Laser Beam Profile Monitor
Focusing Mirror Plasma Sensor Pin-Hole Monitor
Laser Scanner
Light or Laser

Light Sensor

THYSSEN KRUPP STAHL

Figure 30 – Typical process monitoring approach for potential defect identification.

Some companies, including Mazda and Power Lasers, are developing a weld plume monitoring
technology that measures the plasma intensity, bead shape and temperature. Software
algorithms are used to evaluate these parameters on-line and estimate whether or not a defective
part is being produced (Ref. 10). Renault Automation uses a plasma sensor and an IR check that
identifies gap and mismatch edge conditions (Ref. 11).

Nissan has an in process monitoring system that detects pitting and weld underfill and can
identify when the welding parameters deviate from optimal conditions (Ref. 67). This process
uses two sensing systems that sense the intensity of light emission from the laser-induced
plasma and the weld plume.

3.6.3 POROSITY AND PINHOLES

Pinholes are difficult to detect automatically. Thyssen Krupp Stahl, Prototech Laser, and Toyota
have 100% operator inspection of the blanks to check for pinholes and other visual defects such
as blow through. Several system providers and developers also use a CCD camera and laser
beam to check the seam but with limited success in trying to detect porosity and other weld seam
imperfections, such as discontinuities. One TWB producer indicated that their philosophy is to set
the seam checker to “very sensitive”, thereby allowing an operator to manually check all suspect
blanks. When this is done, 90% of the suspect blanks are acceptable.

An ultrasonic technology has shown promise in detecting pinholes, porosity, concavity and gaps
with a diameter greater than 0.2 mm. It can also identify if the edge gap between the blanks is

35
 unacceptable. This equipment, Te mate, is in use at ProCoil. Tailor Steel of America also
indicated that they use ultrasonic testing on 100% of their blanks.

3.7 WELDING PATCH BLANKS

Although there are several viable approaches to attaching patch blanks, such as laser welding or
adhesives, spot welding is the only known method used in production today. Both examples
shown in Figure 10 on page 12 use spot welds applied using an automated carousel. In these
applications, the welding system is fast, producing welded blanks in 8 to 9 seconds per part.
Several important considerations for patch spot welding include part gaging, the number of welds
chosen for the blank, and their location.

Part gaging, or locating the two parts relative to one another, is important for uniform quality. The
“fish” shaped blank on the bottom in Figure 10 is gaged by using locating holes in both blanks.
Two holes near the opposite ends of the patch blank are located with steel pins in the welding
fixture. This method is simple, highly repeatable, and produces the desired result. Blanks that
cannot accommodate holes through them, such as the blank on the top in Figure 10, require
another means for locating. The method used in Figure 10 places the reinforcements on the
fixture under the larger blank with stops in the fixture. This method occasionally results in double
blanks and produces lower location repeatability.

The patch type blanks in Figure 10 show a minimal number of spot welds. The objective of these
welds is to hold the parts together during forming and additional respot welds can be added later.
The longitudinal rail in Figure 10 has twenty additional spot welds added after forming. The small
blank has two spot welds and the larger one has three. These welds are located on the “flat” of
the part as far apart as possible. The flat part area is less subject to forming strain and will be
more likely not to fail during the forming operation.

36
 4.0 MANUFACTURING SYSTEMS AND SUPPLIERS

4.1 MANUFACTURING SYSTEMS - PRODUCTION

Tailor welded blank production has evolved significantly since the mid-1980s. Resistance mash seam
welding has lost favor to CO2 and YAG laser principally due to falling prices, increased laser power, and
the constraints of welding coated steels. Mash welding is still in production in several applications where
it has advantages. Weld designs have also become more complicated with multi-weld and non-linear
welding. These changes have encouraged a number of new welding technologies. Traditional welding
systems began with clamping, straight-line weld lines using either fixed optics or flying optics such as VIL
and Soudronic. Additional lines were developed with “flow-through” capability with high capacity, such as
the Thyssen Conti line. Jig lines were developed for blanks with multiple welds where all the blanks can
be loaded in a single step, such as at Toyota and Tailor Steel of America. Future system development is
focusing on non-linear welding lines that require sophisticated edge tracking, multi-axis weld heads,
complex clamping technology, and precise edge fit-up.

Suppliers in North America and Europe use a mix of commercial welding systems and in-house
proprietary systems. The most common systems are “flow-through” systems wherein blanks are loaded
at one end, run through a series of processes, and unloaded at the other end. Many flow-through
systems also use beam switching when the production volume is high enough to justify the added
investment. Beam switching allows for increased capacity in situations where the weld time exceeds the
load/unload time. If the load/unload time is significant, typically observed from 8 to 20 seconds per cycle,
then the laser can switch to another weld gantry while the first one is re-cycling. Typical flow-through
systems include AWS, Soudronic (Figure 31 on page 38), Thyssen Conti (Figure 33 on page 38), and
VIL. The processing steps include some or all of the following:
• De-stack, sometimes with fanning magnets or devices to check for double blanks;
• Precision edge shear, such as on VIL systems, or edge mashing, only on Soudronic;
• Welding and online process monitoring;
• Dimpling;
• Weld seam cleaning and oiling;
• Turnover;
• Stacking of “good” and “bad” stacks

37
 25

Figure 31 - Soudronic laser shuttle system.

Soudronic Laser
Welding (SOULAS)
Figure 32 - Soudronic SOULAS welding system video.

Figure 33 - Thyssen Conti flow-through system (with jig pallets).

38
Another manufacturing approach is to use shuttle, or indexing, jig systems. These systems are in use by
Renault, Tailor Steel of America, and Futaba. Indexing systems have a single weld tool with indexing
parts, thus eliminating the need for beam switching. These systems usually index into the weld tool when
the opposite side indexes out. In this fashion, blanks can be loaded and unloaded while the opposite
shuttle is in the tool being welded. Secondary processing, such as weld cleaning or dimpling, are often
offline. Tailor Steel of America has built in parallel turnover and stacking stations (Figure 34 below).
Renault Automation (Figure 35 on page 40) has an indexing jig system wherein the gantry operates in
one axis and the jig itself operates on a different axis. This system is capable of curvilinear welding with
the necessary seam tracking and yet to be developed control software.

Figure 34 – Schematic of indexing jig/shuttle system with parallel turnover and stacking stations.

39
 Figure 35 – Schematic of Renault Automation indexing jig system with 2-axis weld capability.

Table 3 (pages 45 and 46) lists several of the major commercial welding systems available and which are
currently in use around the world. See the appendix for specific contact information for these companies.

In Asia, Toyota and Nissan have the most advanced strategies for developing TWB welding systems.
The Japanese companies tend to favor CO2 laser for power, but are looking at Nd:Yag for possible future
systems. Some outside suppliers provide blanks using mash welding.

Nissan has a development path from their Generation I through Generation IV systems (Ref. 40). Major
objectives are to develop robust systems requiring minimal maintenance and containing investment cost
while maintaining current production volume capability (Ref. 10). Nissan currently has Generation II at
Kyushu, U.S., and the UK, and Generation III at Oppama and Tochigi in production. Characteristics
progress from a simple linear gantry system (Generation I, which is now phased out) to a state-of-the-art
jig pallet system with beam switching for multiple straight line, multiple welds (Figure 36 on page 41).
Nissan envisions that their next generation will be Generation IV with curvilinear capability, probably using
a Nd:YAG laser. Because of the merger relationship between Renault and Nissan, Nissan is evaluating
their Generation IV strategy in light of the curvilinear-capabilities of the system at Renault Automation. It
is likely that a single curvilinear system strategy will be chosen.

40
 K sheets/460hr Welding cost:Target 2 cents / inch
Generation IV Generation III

Production Capability
150 Singe linear Single linear &
&
Curve Multiple linear

100
Generation II
Singe linear
50 Generation I
Singe linear
Door inner : weld length 53 inch
0 0.5P P 1.5P 2P 2.5P
Investment Cost

Figure 36 – Nissan TWB welding system development strategy.

Figure 37 - Nissan Generation III welding system.

41
 Nissan Welding
Systems

Figure 38 - NissanGeneration III video.

The Toyota welding systems have not changed significantly since their original development. They
continue to use a family of three systems, small, medium and large, with the majority of applications run
on the medium-size turntable. Their large blank welder was designed primarily for body sides and has
two laser resonators. Toyota indicated that the system is generally underutilized, using only one laser
and making multiple small parts on a single jig. Toyota’s medium size turntable system has three axes,
two on the gantry and one with a rotating laser head, which could be used for curvilinear welds. One of
the shortcomings of the Toyota turntable system is the time it takes to rotate each time it loads a new set
of blanks. This approximately 8.5 seconds is constant for all blanks, regardless of welding time. Tailor
Steel Genk reported a preference for indexing systems over the turntable system because of this indexing
time (Ref. 11). Tailor Steel’s indexing system that began with the Toyota turntable design can be seen at
Tailor Steel of America (shown in Figure 34, page 39). Toyota indicated that they are not pursuing
curvilinear welds.

Toyota is known for using beam weaving during the welding process. Both Tailor Steel Genk and Tailor
Steel of America have experienced mixed success using beam weaving, finding that it slows the welding
process and does not always correct for edge fit-up problems. Even though Toyota continues to use
beam weaving on most of its welding, both Tailor Steel facilities have stopped using it mainly because it
reduces weld speed. One Toyota process in Georgetown, Kentucky was observed welding door inner
panels with beam weaving at approximately 3.0 meters per minute, considerably slower than commercial
speeds of around 7.0 meters per minute.

The Mazda in-house welding system uses a CO2 laser and indexing jig concept. A jig is part-specific
tooling for holding the blanks. The weld system has multi-axis capability with a moving optics, and Mazda
may develop multi-straight line weld applications in the future.

Similar to the Nissan development path, many TWB companies started with simple, usually single-weld
application welding systems. The evolution has been toward multi-weld lines, which often meant
connecting several single-weld gantries, usually with some intermediate edge preparation system.
Several companies today are continuing the evolution into curvilinear system, including:
• ATB (X-Y Held gantry),
• Thyssen Krupp Stahl (jig system),
• Renault Automation (jig system),
• Tailor Steel (Toyota turntable/indexing jig system),
• TWB (jig system)
• AWS

42
 Figure 39 - Layout of Thyssen non-linear welding line that uses jigs.

5.2 INTEGRATED LASER CUTTING AND WELDING (RESEARCH)

The Fraunhofer Institute has been developing a high-power CO2 laser welding system that relies on CO2
laser cutting for edge preparation. The precise edge fit-up provided by laser cutting eliminates the need
for seam tracking. This system is capable of sophisticated shapes, including curvilinear welds, and fast
welding speeds. Part specific jigs are used to hold parts during cutting and welding. The part jigs have a
dimensional window of 2 by 4 meters, allowing for a single body side or multiple smaller parts on a single
jig. The Fraunhofer Institute has welded linear and non-linear welds with this concept: however, a
production version of the equipment has not yet been produced. Generally, this system is seen as having
unique, sophisticated capabilities, but at a somewhat higher price than currently available equipment.

43
Figure 40 - Conceptual Fraunhofer welding system with two CO2 laser resonators – one
for blank cutting and one for welding.

44
 Companies
Power Welding
Name With Edge Prep. Comments
Source Capability
Technology
Automated • Medina Nd:YAG Blank die 3-axis • Dual spot available
Welding • Olympic Laser with vision tracking
Systems Processing and gap validation
(AWS) • Ohio Welded • German subsidiary
Blanks established to build
• Eko Stahl and install in Europe
(Germany)
Nissan • Nissan (Japan, CO2 Blank die 1-axis and • Weld bead monitoring
UK, North multi-axis for defect detection.
America) • Simple, straight line
CO2 welding systems
initially
• Beam switching
systems with part-
specific jigs now in
production
• Working with Renault
Automation in
choosing a single best
approach
• Curvilinear welds
under development
Northelfer • Thyssen Krupp CO2 Blank die 1-axis • “Flow-through” system
(Thyssen Stahl and • Systems available
Conti) • TWB precision only in Thyssen group
• Galvasud shear
Renault • Renault CO2 Blank die 1-axis and • Shuttle system with
Automation multi axis curvilinear capability.
• Working with Nissan
to identify combination
of best technologies.
Soudronic • ProCoil CO2 Mash 1-axis • CCD camera tracking
(Michigan) edges and adaptive control,
• ATB (Souka) weld bead quality
(Netherlands) monitoring
• Cockerill • Developing multi-axis
(Belgium) capability (multi-
• Voest Alpine straight lines) and
(Austria) possible curvilinear
• Ferolene systems for future
(Brasil) • Researching tradeoffs
• Tailor Metal between CO2 and
(Spain) Yag
• Rio Negro • Setting up R&D site in
(Brasil) Michigan
• Tailor Steel
(Belgium)

45
Toyota • Toyota CO2 Blank die Multi-axis • Family of three
(Japan), welding systems (with
• Tailor Steel derivatives from these
(Belgium) three).
• Tailor Steel • All systems currently
(USA) use CO2
• Investigating PALW
and Yag power
sources.
• Curvilinear welds
possible, but not
explored.
VIL • MakAuto CO2 and Precision 1-axis • All systems rely on
• Ohio Welded Nd:YAG Shear precision shear
Blank • Provide weld systems
• Jefferson with either CO2 or
Blanking Yag – customer
• LWB Ltd. (UK) choice.
• Honda (Ohio • Most recent systems
and Canada) developed with Yag.
• Daewoo • Also sell weld system
(Korea) components such as
• TWB precision shear and
automation

Table 3 – Commercially Available TWB Welding Systems

46
 Power Edge Welding
Name Companies Comments
Source Prep. Capability
Thyssen • Thyssen Blank • Multi-axis capability for
Krupp Stahl die curvilinear welds
Honda • Honda of Nd: Yag Precision
America shear
(Ohio)
• Honda
(Japan)

Noble • CO2 Blank die • Mixture of manual and

Industries and high-volume automated
(formerly precision systems.
Utilase) shear
Laser • Laser Weld CO2 Blank die • First production job for
Welding International curvilinear weld (General
International (Prototech) Motors)
(Prototech) • Manual load/unload
Power Lasers • Dofasco CO2 Blank
die and
precision
shear

Table 4 – Proprietary TWB welding systems.

47
5.3 TAILOR WELDED BLANK SUPPLIERS

5.4 NORTH AMERICA

The number of TWB suppliers has grown significantly during the 1990’s, and many of the North
American suppliers have business relationships with steel companies or steel processors. In
1990 there were three suppliers offering a mix of CO2 laser and mash welded blanks. The “Big
2,” Thyssen and Utilase, dominated nearly 100% of the welding market. In 2000 there are
approximately thirteen suppliers spread across seventeen locations (Ref. 81). But the “Big 2,”
now, TWB, formerly Thyssen, and Noble Industries, which acquired Utilase, continue to dominate
market share with about 80% to 90% of the market [Refs. 11, 81). The major commercial
suppliers for TWBs in North America include (see Appendix for contact list):
• Jefferson Blanking (Shiloh Industries)
• MakAuto
• Noble Industries
• Ohio Welded Blank (Shiloh Industries)
• Olympic Laser Processing
• Procoil
• Prototech
• Tailor Steel of America
• TWB

Although still available, mash welding has lost favor to laser, and laser systems are readily
available with either CO2 or Nd:YAG power sources. There is little interest today in mash
welding lines, and the several applications today being welded by mash systems at Thyssen
Krupp Stahl, ATB, Mazda and Toyota are welded on older equipment. Another factor contributing
to the demise is that as fewer systems are available for production, fewer systems are also
available for backup capacity. A list of North American suppliers can be found in the Appendix).

Growth of in-house welding systems at the automotive OEMs has progressed more slowly. In the
early 1990’s, GM installed a VIL CO2 laser system at its Oshawa plant but eventually
discontinued production. Several other installations at GM plants were contemplated but did not
materialize. DaimlerChrysler has successfully installed two Soudronic mash welding systems in
Toluca, Mexico. Ford has not installed any welding systems in North America. The Japanese
transplants have been slightly more aggressive with in-house welding lines at Toyota, with 3 in
Georgetown, Nissan, with 1 in Smryna, and Honda, with 1 in Marysville.

4.3.2 EUROPE

The number of TWB suppliers has grown similarly in Europe, but with several differences. The
majority of the suppliers in Europe are owned by or have strong ties to steel companies.
Approximately 95% of the European welding capacity is owned by three steel conglomerates:
Usinor of French, Thyssen of Germany, and Tailor Steel of Belgium. The philosophy of European
producers has been to vertically integrate TWB supply with steel allowing for “full-service”
support, thus improving the likelihood of selling more steel (Refs. 11, 62). By staying closely
integrated with their larger steel company parents, they are able to offer more design engineering
and technical support when needed.

European companies have been developing acceptance weld guidelines through the consortium
VDI (Ref. 11).

Thyssen Krupp Stahl has the world’s largest production resources with facilities and joint ventures
throughout North America, South America, and Europe. They produce approximately 45% of the

48
European market’s demand, including ten of the parts on the VW Golf. They have mass-
produced TWBs since 1991 with mash and 1992 with CO2 laser, and have facilities or joint
ventures that include:
• 2 facilities in Duisburg Germany;
• Dortmond (Hoest Plantinen);
• A planned facility in Wolfsburg to supply VW;
• TWB in Monroe, Michigan;
• Euroweld joint venture in Italy to supply Fiat;
• GalvaSud in Brazil;
• A planned facility in the UK.

There are a few exceptions wherein automotive OEMs are welding TWBs in-house. Volvo has
traditionally welded many of its blanks in-house. Today, they weld many of their own blanks
using both mash welding, with Soudronic equipment), and their own in-house developed
induction welding lines. A second exception is Renault, which welds blanks in-house at plants in
Douai, Flin, Valladolid, and Sandouville using Renault Automation laser welding equipment. A
third exception is Ford-Cologne where they mash weld the Fiesta engine rail using Soudronic
equipment. Aside from the Renault and Volvo exceptions, the trend by European auto
companies is to purchase TWBs from outside suppliers (Ref. 11).

Some suppliers can support an argument for central supply sources rather than numerous
satellite plants next to the customer. While satellite plants reduce shipping costs and improve
communication, they can be a strain on the supplier. Small suppliers would become vulnerable to
spreading expertise across too many facilities (Ref. 11). Both Thyssen Krupp Stahl and Solblanc
are setting up satellite plants. Voest-Alpine Euro Platinen has indicated an interest in expanding
their operations in Europe and into North America (Ref. 11).

ATB has installed a Held gantry for welding large 4 x 6 meter blanks. Their current application is
a truck roof that is welded down the center due to coil size limitations. This system uses a new
6.0 kw Wegmann laser being promoted as having lower operating costs than other resonators.

The European companies may have some cost advantages over North America because of
several logistical strategies. Similar to the Japanese, many European applications have short
welds that allow them to rely more on blank edge preparation. Consequently, most European
suppliers have blanking capability in-house. The use of blank dies aids in eliminating a
secondary step of precision shearing and often produces more efficient material utilization due to
nesting of blanks. Another advantage is the use of standardized steel pin pallets that reduce
material handling and protect TWBs from damage. Finally, lower inventory levels reduce
inventory holding costs and help to reduce or eliminate the need for dimpling and weld bead
protection from corrosion.

Several European companies are developing non-linear, or curvilinear, welding systems for
applications in the near future. Renault Automation is constructing a system and developing
necessary tracking software (Ref. 11). This system will likely be a derivative of their jig/shuttle
system. Soudronic is also developing a system with curvilinear capability called Soutrac (Ref.
11). Soudronic already has a system capable of multiple straight line “chevron” blanks using their
current CO2 laser system with an adjustment to turn the blank to weld at a different straight-line
angle while continuing the same weld.

Thyssen Krupp Stahl has developed a weld line with the capability to produce non-linear welds.
Early trials in Duisburg have been on multi-straight line welds, but curvilinear welds are possible
with additional developments. This system uses eight jigs that reduce part loading/unloading time
between blanks, but increases investment cost. Flexibility and changeover time may also be
improved through the multiple jig concept (Figure 39, page 43).

49
5.5 ASIA
The Asian market is more integrated than either Europe or North America. All of the in-house
weld systems in Japan are engineered in-house or purchased from another company that
developed it in-house, while Korean companies Hyundai and Daewoo have purchased
commercial systems. The TWB suppliers do not perceive the Korean market as offering much
potential in the near future because of the tendency to produce TWBs in-house. The Japanese
cite several advantages to in-house production:
• Improved communication;
• Lower logistical costs;
• Control over development of the technology.

Ten years ago, there were no outside suppliers in Japan, but today, Toyota alone uses the
following suppliers:
• Yajima;
• Kanto Motors (laser);
• Auto Works (laser);
• Toyota Auto Body (laser and plasma);
• Daihatsu (mash);
• Toyota Iron Works (mash);
• Pacific Industries (plasma), and
• Futaba (laser)

Another company, Toa, has plans to sell blanks to Fuji Heavy Industries. Other Asian auto
companies known to be using TWBs, including Nissan, Honda, Mazda, Daewoo and Hyundai,
weld most applications in-house. Nissan has indicated that Nissan Shatai plans to install a Yag
welding system next year to produce TWBs. There is a slow transition to outside suppliers as the
technology matures and simpler applications, such as single, short welds can be cost justified
outside (Refs. 10, 62).

50
 5.6 SUPPLY LOGISTICS

5.7 PALLETS

Several European auto companies require steel pin pallets for shipment of completed blanks from
the supplier to the stamping plant. VW is standardizing their steel pin pallet design to minimize
material handling costs and to improve logistics (Ref. 11). Currently, all TWBs shipped to VW in
Wolfsburg must be on a common pin pallet. Typical pin pallets weigh 5,000 pounds tare and
25,000 pounds fully loaded, and cost from $1,000 to $3,500 each. Mercedes Benz is
standardizing pin pallets across all their plants to facilitate material handling (Figure 41, below). A
disadvantage of steel pin pallets is the return shipment of empty pallets to the TWB facility. The
Mercedes pallets shown have removable pallet pins to make them more stackable.

Figure 41 – Standardized steel pin pallets used by Mercedes Benz.

5.8 INVENTORY

ATB voluntarily maintains a one-week supply of finished welded blanks (Ref. 11), as their
principal customer, VW, does not specify required inventory buffers. Tailor Steel of Genk
maintains a one-week buffer of finished inventory. Having sufficient pin pallets available for
inventory storage can be a problem and in this instance, blanks are stored on wooden pallets and
transferred to pin pallets prior to shipment.

North American auto companies have indicated a preference for two weeks of finished inventory
at the supplier. In practice they have achieved inventory levels closer to one week because of
steel pin pallet availability from the stamping plants.

51
 The un-welded blank inventory at Toyota is approximately two hours. The finished welded blank
inventory, prior to forming, is typically about three days (Ref. 10) when supplied by outside
vendors. At Georgetown the finished inventory was about 1.5 shifts. Renault also welds many
blanks in-house and minimizes inventory to 3 days of welded blanks, which allows them to
eliminate weld oiling (Ref. 11).

In some cases, large inventories are believed to create problems because of age hardening of
the weld. Maintaining a rotating FIFO inventory will help to minimize this possibility (Ref. 10).

5.9 DIMPLING

Companies have had varying degrees of success using dimples to maintain blank separation.
Most Japanese companies try not to use them at all by having lower stack heights, using pin
pallets to maintain the stack, and using special destacking equipment. Toyota does use dimples
on some mash-welded parts that are supplied by an outside vendor (Ref. 10).

The use of dimples, particularly on large blanks, can offer minimal benefit because they tend to
collapse. The stack weight, banding the pallets, and shipping all contribute to collapsing the
dimples. Larger, oblong dimples tend to hold up better than smaller dimples (see Figure 42
below). North American and European companies tend to require dimples on supplied blanks,
which add from $0.10 to $0.30 per blank.

Figure 42 – Oblong embossment design that tends to hold up well.

5.4 STACK REQUIREMENTS

General Motors' requirements for blank stacks supplied to GM plants (Ref. 95) are:
• Blank to pallet tolerance of +/- 12.5mm;
• Stack shift tolerance of 6.0 mm;
• Blank stagger tolerance of 6.0 mm;
• Stack lean tolerance of 6 mm;
• Stack flatness tolerance of 25 mm.

52
 VW requires stack flatness to be within 30 mm with a blank-to-blank edge tolerance of 2.5 mm
(Ref. 11). ATB believes that these flatness and edge requirements may become a European
standard.

5.5 OTHER

Tailor Steel has chosen to implement CMM technology at Tailor Steel in Belgium, and Tailor Steel
of America. The purpose of this technology is to inspect incoming edge condition at the Holt plant
and to monitor edge condition for process control at the Belgium plant. Both straightness and
camber are inspected.

53
6.0 APPENDIX

1
 6.1 EQUIPMENT SUPPLIER CONTACTS
Company Name & Address
Automated Welding Systems
th
3900 14 . Avenue
Markham, ON Canada L3R 4R2
(800-891-0513)
VIL
145 Swift Road
Addison, IL 60101
(630-916-7772)
Soudronic Ltd.
37408 Hills Tech Dr.
Farmington Hills, MI 48331
(248-848-1756)
Renault Automation
Z.1. du Bois de Iepine – CE 1119
Rue Jules Guesde
F 91 031 Evry Cedes France
(33 1 46 09 30 16)
Nissan:
Shuya Kamahori, Manager
Nissan Motor Co., Ltd.
Technical Center
560-2, Okatskoku, Atsugi City
Kanagawa, 243-01 Japan
(0462 70 1202)
PTR
Precision Technologies, Inc.
120 Post Road
Enfield, CT 06082-5699
Gunter Schubert
(860-741-2281)
Toyota:
Munetaka Toda, General Manager
Toyota Motor Corporation
1, Motomachi, Toyota
Aichi, 471 Japan
(0565 26 3106)
Thyssen Conti:
Dr. Manfred Nagel, Executive VP
Tailor Welded Blanks
1600 Nadeau Road
Monroe, MI 48162
(313 289 6507)

2
 6.2 BLANK SUPPLIERS - NORTH AMERICA

Est. No.
Group Address
Gantries
Comments
Tailor Steel of America
Tailor Steel 1777 Holloway Dr.
3 Shuttle system
(Arbed) Holt, MI 48842
(517-694-9070)
Todd Antenucci, VP Sales & Marketing Formerly Utilase.
10
Noble 20101 Hoover Manual and automated systems
Industries Detroit, MI 48205
5 Manual systems
(313 245 4810)
Thyssen Conti: 10 Thyssen Conti systems
Dr. Manfred Nagel, Executive VP
Thyssen Tailor Welded Blanks
Worthington 1600 Nadeau Road 4 Manual systems
Monroe, MI 48162
(313 289 6507)
ProCoil
National Steel 5260 Haggerty South 4 Soudronic CO2 laser
Canton, MI 48188
Automated Welding Systems
Automated th
3900 14 . Avenue
Welding
Markham, ON Canada 2 AWS Nd:YAG
Systems
L3R 4R2
(AWS)
(800-891-0513)
Toyota Georgetown, Kentucky 3 Toyota turntable systems
Prototech Laser Welding, Inc. Welding prototypes; curvilinear laser
Prototech 18321 Mike C. Court 2 blank welding; adding radius to TWB
Fraser, MI 48026 weld lines
Formerly Magna, now Dofasco;
Powerlasers Ltd.
Production facilities in Concord,
55 Confederation Parkway.
Ontario & Pioneer, Ohio; R&D facility
Dofasco Concord, Ontario 6
in Kitchener, Ontario; design and
L4K 4Y7
build laser systems for auto and
other applications.

3
 Est. No.
Group Address
Gantries
Comments
Aluminum, steel and plastic welding
2 with CO2, Yag, and Diode; some
patch and insert welding
Olympic Laser Processing
U.S. Steel
6331 Schooner Drive 4 AWS weld systems
Group
Belleville, MI 48111
Formerly Medina Blanking.
Soudronic mash welding
Ohio Welded Blank,
7 Soudronic CO2 laser systems
Shiloh Division of Shiloh Industries
AWS systems
Industries 5389 West 130th Street
VIL CO2 system
Cleveland, OH 44130
3 VIL systems
1 VIL system
Makauto Soudronic mash
Division of MakSteel 6 VIL CO2 laser
MakSteel Maksteel Inc. Nd:YAG
7615 Torbram Rd.
2 VIL CO2 laser
Mississauga, Ontario L4T 4A8
Nissan Smyrna, Tennessee 2 Nissan system
Honda Marysville, Ohio 1 Nd:YAG, precision shear

4
 6.3 BLANK SUPPLIERS - EUROPE

Est. No.
Group Gantries
Name/Location Comments
Tailor Steel Genk, Belgium Toyota turntable systems
6
(Arbed) Shuttle system
2 Gent, Belgium Soudronic CO2 laser
2 Bremen, Germany Held shuttle systems
4 Zaragoza, Spain Soudronic CO2 laser
CORUS 1 Port Talbot, Great Britain Held
3 Wolverhampton, Great Britain Power Lasers
Bunschoten, Netherlands Soudronic CO2 laser
3
Soudronic mash
Renault 2 Douai, France Renault CO2 laser
Sandouville, France Renault Automation – CO2
~ 2?
shuttle system
2 Flin, France Renault CO2 laser
1 Guyancourt, France, Techno Centre Renault 3-D CO2 lab system
Valladolid, Spain Renault Automation CO2
2 shuttle system
Renault circular weld system
Thyssen Fugetechnik Huttenheim, Duisburg, Conti systems
6
Krupp Germany New Nd:YAG for non-linear
Fugetechnik Bruckhausen, Duisburg, Conti system
1
Germany
2 Dortmond, Germany Held shuttle system
4 Wolfsburg, Germany Conti systems
2 Euroweld, Turin, Italy Shuttle system
Usinor Cockerill, Liege, Belgium Soudronic CO2 laser
2
Patch spot weld system
Eko Stahl, Eisenhuettenstadt, AWS Ultima Nd:YAG
1 Germany AWS manual system
Include a blanking press
3 Solblank, Barcelona Sollac Polymatic systems
6 Solblanc, Ukange, France Sollac Polymatic systems

5
 Est. No.
Group Gantries
Name/Location Comments
LWB, Ltd., Birmingham, Great Britain Sollac Polymatic
Joint venture with Steels &
2
Alloys
VIL Nd:YAG system on order
Voest Linz, Austria Soudronic CO2 laser
9
Europlatinen
Salzgitter Salzgitter, Germany Soudronic CO2 laser
3
Europlatinen
Nissan 2 Sunderland, Great Britain Nissan CO2 shuttle system

6
 6.4 BLANK SUPPLIERS - SOUTH AMERICA

Est. No.
Group Gantries
Name/Location Comments
1 Ferrolene, Brazil Soudronic CO2 laser
USIMINAS 2 Rio Negro, Brazil Soudronic CO2 laser
CSN 1 GalvaSud, Brazil Nothelfer Conti
Usinor Gonvarri Renault Automation shuttle
1
system

7
 6.5 BLANK SUPPLIERS - ASIA

Est. No.
Name/Location Comments
Gantries
Auto Works Laser
~1 Daewoo, Korea VIL CO2 laser
Daihatsu Mash
~3 Futaba, Japan In-house CO2 shuttle
~1 Honda, Japan Unknown
~1 Hyundai, Korea Nothelfer Conti
Kanto Motors Laser
~6 Nissan, Japan CO2 laser
~1 Nissan Shatai Plans Yag welding for Nissan in 2001
Pacific Industries Plasma
~1 Toa, Japan Purchased CO2 laser technology from Futaba
Toyota, Japan Three families of systems (small jig, turntable, large
~ 12
jig)
Toyota Auto Body Laser and plasma
Toyota Iron Works Mash
~1 Yajima, Japan ?

8
 6.6 BIBLIOGRAPHY

No. AUTHOR COMPANY TITLE Year Publication Pages Abstract

1 Adonyi, Y.; Laser-Welded Steel 1996 Automotive pp.
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2 Andersen, Aalborg Method for Preparation 1997 NIST Special pp. 77- One of the most important characteristics
H.J.; Holm, University of Laser Welding publication 88 of the laser welding process is the shape
H. Control 923 of the heat distribution, which only affects a
very deep and narrow area near the weld
groove. Hence to achieve a satisfactory
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the process parameters (e.g., welding
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small disturbances in the workpiece
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3 Anon Mass Produced Laser 1998 Sheet Metal pp. 12-
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First
4 Antenucci, Noble The State of the Industry 1999 29 total
Todd International,
Ltd.
5 Aristotile, Centro Feasibility Study on the 1998 Welding pp. This paper describes a feasibility study on
R.; Fersini, Sviluppo Application of Laser Butt International 539- the integration of a laser source as an
M.; Bosi, Materiali; Welding of Tubes to a 547 automatic unit for circumferential butt
C.; Ansaldo Pipe Coil Production welding of tubes on pipe coil production
Colombo, Industria; Line lines, immediately prior to the cold-bending
E.; Giolfo, Ansaldo station…
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6 Ashley, Steel Cars Face a 1997 Mechanical pp. 56- The effort of car industries in the United
Steven Weighty Decision Engineering 61 States to improve automotive gas mileage
by reducing the weight of steel body
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9
No. AUTHOR COMPANY TITLE Year Publication Pages Abstract
7 Auty, T. VIL Laser Welded Tailored 1998 Sheet Metal pp. 14, Critical stress regions of automotive
Blanks--A Practical Industries 16, 18, components (such as doors) can be
Guide 20 reinforced economically by using tailored
blanks in which a thicker section is laser
welded to a thinner panel to produce a
compound blank with resultant quality
improvements, cost and weight savings
and reduction in piece parts...
8 Bachmann, Rofin-Sinar High Power Diode 1999 ALAW 47 total
Friedrich Laser GmbH Lasers and Their Detroit
G. Applications
9 Bagger, C.; Institute for Forming Tests for Laser 1998 Proceedings pp. 29- In this paper different means for testing the
Rasmusse Product Welded Blanks 31st ISATA 36 formability of new material combinations
n, M.; Development Conference used as tailored blanks in the automotive
Olsen, F. industry are presented.
10 Baron, Jay; University of Trip Report 1999 Report 10 total Visit to Japan - June 8-18, 1999
Hammett, Michigan;
Pat; Auto/Steel
Geddes, Partnership
Steve;
Noel, Jack
11 Baron, Jay; University of Tailor Welded Blank 1999 Presentation 70 total Benchmark Trip to Europe - October 4-15,
Noel, Jack Michigan; Investigation 1999
Auto/Steel
Partnership
12 Belforte, D. Non-Linear Welding 1998 Industrial pp. 9- The reasons for the purchase of the first
A. System Attracts Laser 11 Nd:YAG laser-powered tailor blank welder
Customers Review from Automated Welding Systems Inc. and
Soudronic mash seam welders by Medina
Blanking Corp (Mansfield, OH, USA) for
joining dissimilar metals to produce tailor
welded blanks for subsequent automotive
component fabrication operations are
discussed.
13 Blair, S.J.; British Steel Numerical Simulation of 1997 Automotive pp.
Tran, T. Press Forming Laser- Automation 337-
Welded Tailored Blanks Limited 344

10
14 Blumel, Numerical Modeling of 1999 SAE Tailored blank applications have become
Klaus W.; Tailored Blank International more and more important for the advanced
Ufermann, Applications for Congress lightweight and cost-effective steel
Peter; Autobody Components and automobile body. During the last decade,
Graham, Exposition, the production of tailored blanks with a
John Detroit, straight weldline has been constantly
Michigan increasing because their technical and
economical advantages are well accepted
by automobile manufacturers...
15 Blundell, N. Coventry Arc Takes Laser 1998 Materials pp. The use of plasma arc augmented laser
University, Welding Into New World 537- welding (PALW) to enhance the
UK Territory 538 performance of industrial lasers while
retaining the weld quality for manufacturing
applications is described. The advantages
of PALW: higher welding speed, faster
production time, reduced processing costs
and higher weld quality are discussed. Its
application to tailor welded blanks, welding
A1 alloys and lap welding of Zn coated
material is discussed.
16 Buchholz, USLAB: Proves Lighter 1998 Automotive p. 36 The Ultralight Steel Auto Body (ULSAB)
Kami is Stronger Engineering structure car has a mass of about 1341 kg,
(Detroit International without any secondary mass savings.
Editor) ULSAB's consortium of 35 sheet steel
producers from 18 countries produced 13
identical body structures to demonstrate
steel as a lightweight material with torsion
and bending strengths beyond 9 of today's
midsize sedans.
17 Chen, Kuo- Sheet Metal Stamping 1996 Special This current publication addresses the
Kuang; Sa, for Automotive Publication - following subjects: forming limit diagram,
Chung-Yeh Applications SAE modeling of sheet metal forming,
springback and its control, optimum blank
design, tailor welded blanks, coated sheet
steel, aluminum alloy sheets, tube
bending, binder force system, binder
design, and tool design...

11
18 Corrias, Fiat Laser-Welded Tailored 1997 International In this paper, we present the results of a
Silvio; Blanks for Trucks: A Body technical and economical feasibility
Faccio, Technical and Engineering evaluation of a laser-welded tailored blank
Francesco; Economical Feasibility Conference application in an IVECO truck cab. The
Gallinaro, Analysis and different aspects related to the economic
Gaetano; Exposition comparison between a traditional and a
Savio, tailored blank solution are analyzed.
Pierino
19 Das, Sujit Oak Ridge The Economic Viability 2000 Report 9 total
National of Aluminum Joining prepared for
Laboratory Technologies USDOE
20 Diehm, TWB Worldwide Applications 1996 Automotive In the early 1980's, the first laser welded
Oliver Company of Laser Welded Blanks Laser blank application was introduced through
Applications Thyssen Stahl AG; an oversize panel was
Workshop manufactured for the Audi 100. Two years
after the introduction of several similar
gauge Tailor Welded Blanks, applications
included the use of different steel grades,
thicknesses and coatings...
21 Dodd, A. Lumonics Laser-Welded Blanks 1998 Manufacturin pp. 76- Tailor welded blanks promise significant
Gain Ground g 82 cost savings for automakers by
Engineering streamlining the fabrication of automotive
vehicle bodies. Manufacturers currently
employ four types of joining processes to
weld coated-steel tailored blanks: mash
seam welding, electron beam welding, and
laser welding...
22 Dodd, A.; Lumonics; Tailored Blank Welding 1997 Fabricator pp. 70- The use of tailored blank welding, a
Stafford, D. Honda of Systems for Auto 73 process for joining different types and/or
American Manufacturing thicknesses of steel together for later
Manufacturin stamping of one finished part. The factors
g, Inc. USA considered by Honda of America
Manufacturing Inc. in selecting a Nd:YAG
laser blank welding system with fiber-optic
delivery for the production of door inners
are examined, and process procedures
used in blank welding of 0.7 and 1.4 mm
thickness steel sheet are described.

12
23 Ferguson, Automated Another Viewpoint; 1997 Automotive 6 total
Norm Welding Automated Blank Laser
Systems, Inc. Welding Systems - Applications
Using Nd:YAG Lasers Workshop
1997
24 Gatenby, Alcan Aluminum-Magnesium 1997 International The aluminum magnesium or 5XXX alloys
Kevin M.; International Alloys for Automotive Body in sheet form have been considered for
Court, Ltd. Applications--Design Engineering some time to be the most appropriate
Stephen Considerations and Conference choice for vehicle structures as they offer
A.; Materials Selection and attractive combinations of formability,
Altshuller, Exposition strength, weldability and corrosion
Bernie resistance…
25 Gerhard Haus Der Automotive Door 1999 Presentation 51 total
Tecklenbur Technik E.V. Systems: Vision for
g Future Development
26 Glagola, Reynolds Applications of 1996 29th pp. The application of tailor welded blanks to
M.A.; Metals Aluminum GTA Welded International 781- automobiles has grown substantially in the
Pickering, Tailored Blanks: Case Symposium 789 last ten years. In an effort to reduce
E.R. Studies Comparing on weight and save cost, steel tailored blanks
Processes and Materials Automotive are increasingly used to reduce part count,
Technology weight, offal and assembly costs…
& Automation
27 Gu, University of A Statistical Approach to 1996 Journal of pp. Acoustic emission at frequencies between
Hongping; Waterloo Acoustic Monitoring of Physics 556- 20 Hz and 20 kHz during CO/2 laser
Duley, Laser Welding 560 welding of steel contains important
W.W. diagnostic information related to weld
morphology, depth of penetration and
heat-affected zone…
28 Haran, Heriot-Watt Process-Control in 1996 Laser Described is an optical sensor for process
F.M.; University Laser Welding Utilizing Institute of monitoring of Nd:YAG laser welding (of
Hand, Optical Signal America mild steel). This sensor detects the
D.P.; Oscillations broadband radiation produced by the
Peters, C.; welding process, dividing it into broad
Jones, spectral bands (designated as UV/visible
J.D.C. and IR). Fourier analysis is used to
investigate an oscillatory intensity
modulation of the optical signals...

13
29 Heidbuchel Thyssen Process for Marrying 1997 International There will be a significant increase in the
, Peter; Stahl AG Two Parts Prior to Body application of "tailored blanks" in order to
Wonneber Laser-Beam Welding of Engineering put existing lightweight automobile
ger, Ingo; Circular and Non Conference concepts into practice. Tailored blanks
Mertens, Circular "Tailored and consist of several individual sheets
Axel; Alber, Blanks" Exposition combined in different thicknesses or steel
Gerhard grades welded by means of laser-beam
energy...
30 Hong, J.P.; Formability Study on 1997 Proceedings pp.
Oh, S.-I.; Weld Line Location and of the 295-
Kim, H.-Y. Movement of Laser- International 300
Tailored Welded Blanks Pacific
Conference
on
Automotive
Engineering
31 Hornig, J. BMW Laser Applications and 1999 ALAW 3 total
Strategies at BMW Detroit
32 Hsu, Rey; Fraunhofer New System Concepts 1998 Society of pp. The demand for the use of tailor welded
Heinemann Resource for Steel and Aluminum Automotive 269- blanks in the automotive industry continues
, Stefan Center Tailored Blank Welding Engineers 273 to grow. The competition in this business
is also growing. In order to be competitive,
a cost effective and reliable welding
system is critical.
33 Irving, B. Laser Beam Welding 1997 Welding pp. 35- Despite its high initial cost, laser beam
Shifts Into High Gear Journal 40 welding is being recognized as the best
method for many production lines. The
automotive industry is becoming a bigger
believer, with more lines being added
every day for weld transmissions, mufflers
and many other products...
34 Irving, Bob Welding Interest in Welded 1998 Welding pp. 31- Automobile companies worldwide are
Journal, Aluminum Automobiles Journal 35 taking a serious look at producing all-
contributing Gathers Momentum aluminum vehicles…
editor Worldwide

14
35 Ishihara, Sanyo Tailored Blank Welding 1997 International Tailored blank welding is coming to a
Loichi; Machine of Vibration Damping Body turning point. It is not easy to find a
Kubota, Works, Ltd. Steel Engineering profitable application in this technique
Koji Conference matching the expensive investment cost
and except the common adoption like door
Exposition inner or engine compartment rail…
36 Jansen, Utilase Blank Tailored Blanks: A Key 1997 Automotive 56 total
Steven Welding Technology for Light Laser
Technologies Weight Steel Autobody Applications
Structures Workshop
1997
37 Jansen, Utilase Blank Formability of Laser 1996 Automotive 37 total
Steven Welding Welded Blanks Laser
Technologies Applications
Workshop
1996
38 Jansen, Noble Metal Automated Inspection of 1999 Automated Laser welded sheet metal blanks have
Steven W.; Processing, Laser Welded Blanks Inspection of been inspected for weld integrity using
Liu, Yi; inc. Laser many different approaches. To date,
Camplin, Welded visual inspection by human operators has
Ken; Geier, Blanks been the most reliable method to detect
Dan weld defects. However, the ever
increasing application of laser welded
blanks in automotive body components
has lead to larger blank sizes and
volumes, resulting in the automation of the
laser blank welding process...
39 Jones, Tim Tailor Blank - European 1997 Memo 3 total European steel makers with existing or
Scene imminent capability in tailored blanks are
Thyssen, Tailor Steel (Sidmar/Arbed
Group), Krupp-Hoesch, Voest-Alpine,
Sollac, Hoogovens (ATB), and Cockerill-
Sambre. Equipment suppliers looking to
supply/partner with European steel
interests include Powerlaser/Triam, VIL,
and Utilaser.

15
40 Kamahori, Nissan Motor Nissan's Challenge in 2000 Automotive 21 total
Shuya Co., Ltd. Building the Most Lean Laser
System for Tailor Applications
Welded Blanks Workshop
Production 2000
41 Khaleel, Pacific Weldability, Formability 2000 Presentation 46 total
Moe; Northwest and Structural
Davies, National Performance of Thin
Rich Laboratory Gage High Strength
Tailor Welded Blanks
42 Kim, H.Y.; Kangwon Stamping Analyses and 1998 Metals and pp. Computer simulations and test trials are
Shin, Y.S.; National Die Design of Laser Materials 871- carried out to get the optimal conditions of
Kim, K.H.; University, Welded Automotive 877 the design for the stamping of the laser
Cho, W.S. South Korea Body tailor welded automotive body panels.
Through test trials with new manufactured
die for tailor welded blanks (TWB), the
effects of the initial position of blank, blank
holding force, drawbead shape, and corner
radius are investigated...
43 Kinsey, Northwestern New Apparatus and 1999 SAE pp. 31- Tailored-welded blanks offer a unique
Brad; Liu, University Method for Forming International 37 opportunity to reduce manufacturing costs,
Zhihong; Tailor-Welded Blanks Congress decrease vehicle weight, and improve the
Cao, Jian and quality of stampings through the
Exposition, consolidation of multiple-formed, then
Detroit, welded, parts into a single stamping…
Michigan
44 Kluft, Prometec on-line Process 1997 International As visual monitoring of the seam roots of
Werner; GmbH Monitoring of the Laser Body pipes and other closed sections during
Boerger, Welding of Sheet Metal Engineering laser welding is difficult and usually
Peter; Via Analysis Conference impossible, a method of controlling seam
Schwartz, and root formation via on-line monitoring of the
Reinhold; Exposition plasma radiation above the workpiece from
Cremer, the machining side has been developed...
Volker
45 Kochan, Automotive Tailored Blank 1997 Automotive 1 total
Anna News Europe Technology Expands News Europe

16
46 Kristensen, Evaluation of Laser 1996 International pp. 48- For the welding of structural steels high
Jens Welds in Structural Journal for 54 power laser welding offers many
Klaestrup; Steels the Joining of advantages in comparison with traditional
Borggreen, Materials processes. The advantages include high
Kjeld productivity, limited distortion and low filler
metal consumption…
47 Kubel, Ed Manufacturers Want 1997 Manufacturin pp. 38- Tailor welded blanks (TWBs) present an
More Tailored Blanks g 42, 44- important step by which manufacturers can
Engineering 45 optimize weight reduction, dimensional
control, nesting accuracy, scrap
management, and manufacturability at a
reasonable cost. Current applications of
TWBs include body side frames, door inner
panels, motor compartment rails, center
pillar inner panels, and wheelhouse shock-
tower panels.
48 Kubota, K. Isuzu Motors, Laser Welding 1997 JSAE pp. Vibration damping sheet is made by
Ltd. Technology of Vibration Review 415- laminating a plastic sheet in between steel
Damping Steel Sheet for 157 sheets. Because of this structure, laser
Tailored Blanking welding quality is considered difficult to
Method assure in actual use…
49 Kuepper, Stiefelmayer, New Concepts in Laser 1998 6th Annual 8 total
Frank W. Inc. Blank Welding Automotive
Manufacturing Systems Laser
Applications
Workshop
1998 (ALAW
'98)
Proceedings
50 Kukui, K.; Formability Fatigue 1996 IBEC pp.
Uchihara, Performance and Conference - 100-
M.; Corrosion Resistance of Materials and 105
Takahashi, Tailor Welded Blanks Body Testing
M.; Kurita,
M.

17
51 Kusaka, Quality of High Power 1998 Proceedings 14 pp Carbon steel and various stainless steels
Shuichi; Laser Welded Line Pipe of the were Laser welded in production line and
Shinbo, International the weld mechanical and chemical
Yukio; Conference properties were evaluated to confirm the
Sekine, on Offshore quality of Laser welding…
Yukio; Mechanics
Kojima,
Shinji;
Ohwaki,
Joji
52 Langerak, Hoogovens The Use of Steel and 1997 Automotive pp. 3- In today's sheet metal industry, it is current
Nico A.J. Aluminum in the Next Body 10 practice for the metal supplier to become
Generation Auto Bodies Materials closely involved with the design and
(IBEC '97) production of sheet metal parts. During
the design and production stage, technical
support is supplied relating to material
selection design of parts, tooling and
processing parameters...
53 Lankalapall Model-Based Laser 1997 Welding in pp. Penetration depth is an important factor
i, Kishire Weld Penetration Depth the World 304- critical to the quality of a laser weld. In this
Estimation 313 paper, a model-based technique for
penetration depth estimation by measuring
the workpiece temperatures using infrared
sensors is proposed…
54 Lankalapall Purdue A Model for Estimating 1996 Journal of pp. Penetration depth is one of the most
i, Kishire University; Penetration Depth of Physics 1831- important factors critical to the quality of a
N.; Tu, Jay Ford Motor Laser Welding 1841 laser weld. However, no on-line, non-
F.; Gartner, Company Processes destructive method exists by which to
Mark inspect this quantity. Indirect, model-
based estimation schemes are feasible for
monitoring laser welding processes...
55 Lee, Andy Dofasco Inc. Tailor Welded Blank 1996 SAE pp. 91- Tailor welded blanks (TWB) afford better
P.; Technology for International 102 utilization of sheet steel automotive and
Feltham, Automotive Applications Congress other applications. However, forming
Erick; Van and behavior can be complicated because of
Deventer, Exposition, the interactions between the different sheet
Jon Detroit, steels comprising the TWB and the
Michigan welding processes used...

18
56 Lee, C.H.; Korea Optimum Design of 1998 Metals and pp. Design of weld line in tailor welded blanks
Huh, H; Advanced Tailor Welded Blanks in Materials 458- is indispensable for good manufacturing of
Han, S.S.; Institute of Sheet Metal Forming 463 stamped parts as assigned, since the initial
Kwon, O. Science and Processes by Inverse weld line is distorted severely during the
Technology; Finite Element Analysis forming process. The initial weld line has
Pohang Iron to be determined such that desired weld
& Steel line in a formed part can be obtained...
57 Leong, Argonne Low Cost Laser Weld 1997 Automotive 18 total
Keng H. National Monitoring System Laser
Laboratory, Applications
Laser Workshop
Applications 1997
Laboratory,
Technology
Development
Division
58 Li, L.; Plasma Charge Sensor 1996 Measuremen pp. Laser keyhole welding is an important
Brookfield, for In-process, Non- t Science & 615- modern manufacturing technology. During
D.J.; contact Monitoring of the Technology 626 such welding a plasma cloud is generated
Steen, Laser Welding Process and the behavior of this plasma is closely
W.M. coupled to the behavior of the weld…
59 Liu, Yi Utilase Blank The Integration of Laser 1996 Automotive 5 total
Welding Blank Welding and QS- Laser
Technologies 9000 Applications
Workshop
1996
60 Loeffler, Trumpf Laser Global Laser 1999 Automotive 14 total
Klaus Technology Innovations with Laser
Center Nd:YAG Lasers and Application
Their Applications on Workshop
Components in the
Automotive Industry
61 Marron, G.; Sollac A New Concept for 1999 SAE Usually, wheels' dimensions are based on
Verrier, P. Lighter Steel Wheels International fatigue or impact loading and thus lead to
Congress one steel grade and one thickness. The
and use of tailored laser blanks permits wheel
Exposition, weight to be reduced considerably. Rims
Detroit, can be divided into different areas subject
Michigan to different in-service stresses...

19
62 Martin, Automated Welding 2000 Report 19 total
John Systems Incorporated
63 Mettke, Monitoring Nd:YAG and 1998 Conference pp. 202 An image system was developed that
Christoph; CO/2 Laser Weld on Lasers offered real time capability to determine
Ng, Eng S.; Quality and Electro- weld quality via measurement of the weld
Watson, Optics width, surface roughness and heat affected
Ian A. Europe - zone. The system comprised an
Technical inexpensive CCD camera, acquisition and
Digest processing boards…
64 Mohrbache OCAS N.V. Design and 1997 International The tailored blank is a strategic steel flat
r, Hardy; Manufacturing Issues of Body product designed to reduce the weight of
Rubben, Nonlinear Welded Engineering vehicles and to optimize the structural
Kris; De Tailored Blanks Conference properties and the assembly by part
Rycke, and integration. In both respects, the ULSAB
Igor; Exposition study, a joint effort of the world steel
leirman, industry and Porsche Engineering
Etienne Services, has indicated the significant
potential offered by tailored blanks...
65 Mombo- TC Arts and High-Speed-High-Power 1996 Automotive 15 total
Caristan, Laserfacture Laser Lap Welding for Laser
J.C. s Tailored Blanks Applications
Workshop
1996
66 Mombo- TC Arts and Improved Laser Lap 1997 International An improvement of the laser lap welding of
Caristan, Laserfacture Welding of Galvanized Body galvanized sheet steel is investigated
Jean- s Steel Engineering experimentally. The method proposed
Charles Conference consists of overlapping two sheet metals of
and possibly different thicknesses or
Exposition metallurgies, and of controlling the width of
overlap…
67 Mori, K.; Nissan Detection of Weld 1997 Welding pp. This paper describes an in-process system
Sakamoto, Motors Defects in Tailored International 628- developed to monitor the quality of CO2
H.; Blanks: Development of 632 laser welding. It incorporates two photo
Miyamato, an In-Process sensors aligned at different angles to
I. Monitoring System for detect the long-term power stability and
Laser Welding underfill and pitting defects and has been
used on a production line for tailored blank
welding of automotive parts since 1993...

20
68 Mori, Inprocess Monitoring of 1997 Journal of pp. A novel in-process monitoring system
Kiyokazu; Laser Welding by the Laser 155- employing two detectors set above the
Miyamoto, Analysis of Ripples in Applications 159 workpiece at different aiming angles of 5
Isamu the Plasma Emission degree and 75 degree has been developed
to detect whether or not CO/2 laser
welding fully penetrates through to the
back surface of steel sheets...
69 Mueller, University of On-Line Process 1997 International The common use of laser beam welding in
Matthias.; Stuttgart; Monitoring and Control Body industrial applications allows on-line, non-
Dausinger, Jurca of Laser Welding Engineering descriptive quality assurance based on
Friedrich; Optoelektroni Conference reliable indicators. A new method uses the
Griebsch, k and relationship between the geometry of the
Juergen Exposition keyhole and emitted laser light to control
welding depth and to monitor inner seam
defects...
70 Naeem, Lumonics Tailored Blank Welding 1997 International Tailored blanks have made a great impact
Mohamme Ltd. With a 4-kW CW Body on pressed sheet components in the
d Nd:YAG Laser Engineering automotive industry. Larger pressings can
Conference be made than with standard-sized sheets
and and dissimilar steel types or thicknesses
Exposition can be joined. Resulting benefits are
improved material use, potential weight
saving and a reduction in subsequent
assembly operations...
71 Nagel, Tailor New Developments in 2000 Automotive 40 total
Manfred Welded Laser Tailor Blanking Laser
Blanks Applications
Workshop
2000
72 Nagel, Thyssen Production and 1997 International The demand for weight reduction and
Manfred; Lasertechnik Application of Aluminum Body increasing requirements of passive safety
Fischer, Tailored Blanks Engineering of automobiles forces the use of
Rainer; Conference lightweight vehicle components and new
Lowen, and manufacturing processes. Besides the
Joachim; Exposition weight reduction there is also a priority to
Straube, meet the cost targets...
Oliver

21
73 Nava- Integration of Real Time 1997 Journal of pp. 95- The automation of laser welding processes
Rudiger, Quality Control Laser 102 requires the control of the various process
E.; Houlot, Systems in a Welding Applications components as well as the control of the
M. Process laser-material interaction. These systems
are essential for ensuring the quality of the
weld seam as they are able to react to
dynamic fluctuations during the process...
74 Neiheisel, Armco Inc. Operating, Maintenance, 1996 SAE Paper The paper describes a full production laser
G.L. USA and Productivity Data 962351 tailored-blank welding system and provides
from a Full Production some operating, maintenance and
Laser Blank Welding productivity data.
System
75 Ninforge, Research Improvement of Tailored 1998 Proceedings pp. Tailored welded blanks are increasingly
D.; and Blank Stamping by 20th IDDRG 511- being used in the motor vehicle sector, the
Dawance, Development Using a Control and 519 purpose of these blanks being to reduce
J. Cockerill Localization of the weight and production costs by means of a
Sambre; Blank-Holder reduction in the number of parts to be
Cockerill assembled…
Sambre
Tailored
Banks
76 Oh, S.I.; Seoul Applications of 1998 Metals and pp. Sheet metal forming is one of the most
Lee, J.K; National Simulation Techniques Materials 583- widely used processes in manufacturing.
Kang, J.J.; University; to Metal Forming 592 Traditional die design practice based on
Hong, J.P. Kia Motors Processes trial and error method is time consuming
and expensive. For this reason, the
simulation technique based on finite
element method (FEM) becomes more
popular to develop and optimize die
design...
77 Pohl, T.; University Laser Beam Welding of 1997 Proceedings pp. In mass production of car bodies laser
Schultz, M. Erlangen- Aluminum Alloys for Laser 181- beam welding offers different advantages
Nuremberg Light Weight Structures Assisted Net 192 as for example high feed rate, high weld
Using Co2 and Nd:YAG- Shape quality and minimized heat affected zone.
Laser Systems Engineering It is applied to different production
2 purposes as e.g. for the welding of tailored
blanks, which are an important element of
net shape engineering nowadays...

22
78 Ponschab, Voest-Alpine Advantages and First 1997 International Welded blanks for the body-in-white of
Hellfried; Stahl; Experiences with a New Body automobile are increasingly gaining
Hinterhoelz Soudronic Technology for the Engineering importance. The successful use of tailored
l, Kurt; Production of Laser- Conference blanks instead of single pressed parts…
Muellner, Welded Blanks and
Arthur; Exposition
Radlmayr,
Karl;
Szinyur,
Johann;
Corrodi,
Rudolf;
Sommer,
Dieter
79 Posseln, Tailored Blanks 1998 Proc. Neuere pp.
T.; Entwicklunge 503-
Glasbrenn n in der 521
er, B.; Blechumform
Werkzeugt ung, Fellbach
echnische,
MaBnahme
n beim
Ziehen von
80 Rapp, J.; University of Laser Beam Welding of 1996 Proceedings pp. 97- Laser beam welding of aluminum alloys is
Dausinger, Stuttgart Aluminum Alloys for ECLAT 106 rendered difficult by their specific material
H. Hugel Light Weight Structures (European properties. On the basis of a fundamental
Using CO2 and Conference understanding of the relevant technological
Nd:YAG-Laser Systems on Laser and metallurgical mechanisms, guidelines
Treatment of for a successful adaptation of the welding
Materials) process are offered...
81 Ream, Worthington Tailored Blank Welding 1999 Presented at 26 total
Stanley L. Industries/T in North America, 1999 7th Annual
WB Industry Review Automotive
Laser
Applications
Workshop
'99

23
82 Ream, TWB/Worthin Comparative Analysis 1997 Automotive 31 total
Stanley L. gton YAG vs. CO2 Lasers for Laser
Industries Tailor Blank Welding Applications
Workshop
1997
83 Ream, TWB/Worthin Weld Quality Monitoring 1996 Automotive 14 total
Stanley L. gton for Tailor Welded Blanks Laser
Industries Applications
Workshop
1996
84 Robertson, USS, Olympic in Joint 1996 American p. 4 In joint study. (U.S. Steel Group, Olympic
Scott Study Metal Market Steel Inc. considering joint venture to
produce laser- welded blanks of a joint
venture is being discussed because of the
growth of the market for laser -welded
blanks. "The blanks offer the opportunity
to bring all the advantages of steel to an
automotive...
85 Sakurai, Nissan Motor Stretch Formability of 1997 International In order to investigate the stretch
Hiroshi; Co. Ltd. Laser- Welded Blanks Body formability of laser- welded blanks, the
Sugiyama, Engineering hemispherical punch stretching test was
Takashi; Conference performed and the analysis was carried out
Takahashi, and using finite…
Susumu; Exposition
Shibata,
Kimihiro
86 Saran, M.J. Proceedings of the 1998 1998 Development The proceedings contain 19 papers.
(Ed.); SAE International s in Sheet Topics discussed include stamping surface
Meuleman, Congress & Exposition Metal quality, metal forming, process
D.J. (Ed.) Stamping; optimization, computer simulation, cost
SAE Special modeling, tubular hydroforming and
Publications economic evaluation of the hydroforming
technology.
87 Saunders, General Forming of Tailor- 1996 Metallurgical pp. The issues governing the failure modes
F.I.; Motors Welded Blanks and Materials 2605- and the formability of tailor-welded blanks
Wagoner, Corp.; Ohio Transactions 2616 used in the automotive industry were
R.H. State A studied. Blanks with two combinations of
University parent material were considered.

24
88 Scriven, University of Relative Influence of 1997 Ironmaking pp. 79-
P.J.; Wales Sheet Rolling Direction and 83
Brandon, (Swansea) and Weld Orientation on Steelmaking
J.A.; Formability of Laser
Williams, Welded Steel Sheet
N.T.
89 Scriven, University of Influence of Weld 1996 Ironmaking pp.
P.J.; Wales Orientation on Forming and 177-
Brandon, (Swansea) Limit Diagram of Steelmaking 182
J.A.; Similar/Dissimilar
Williams, Thickness Laser Welded
N.T. Joints
90 Shi, Ming National Formability Comparison 1998 6th Annual 21 total
F. Steel Between laser and Automotive
Corporation, Electron Beam Welded Laser
Product Blanks Applications
Application Workshop
Center 1998 (ALAW
'98)
Proceedings
91 Shimbo, Development of High 1997 SEAISI pp. 31- NKK has installed the world's first 25k W
Y.; Ono, Power Laser Pipe Quarterly 37 laser welding machines at its 24-inch pipe
M.; Welding Process mill at the Keihin Works. High-power laser
Shiozaki, pipe welding process with maintaining high
T.; productivity while assuring uniform welds
Ohmura, with the base metal has been started to
M.; Sekine, develop...
Y.;
Nagahama
, H.;
Kohno, K.
92 Shulkin, Design for Temporal 1997 Ph.D. Thesis, A design was developed for a
L.B. and Spatial Variation of Ohio State hydraulic/nitrogen blank holder pressure
Blank Holder Pressure University (BHP) control system for sheet metal
in Sheet Metal Forming forming (e.g. of tailor-welded and non-
welded sheet metal parts made from steel
and aluminum). A systematic approach
was used to design elastic blank holders
and multi-point blank holder control
systems...

25
93 Simpson, Bethlehem Corrosion Performance 1998 Corrosion 98 pp. 745 The purpose of this study was to evaluate
T.C.; Steel; Ford of Tailor Welded Blanks the corrosion performance of tailor welded
Hoffman, Motor blanks as a function of the type of weld.
J.D.; Company Cosmetic and perforation corrosion
Soreide, L.; resistance of coated sheet products
Meyer, containing mash-seam and laser welds
D.H. were evaluated using the GM954OP-
Method B and SAE J2334 laboratory
corrosion tests...
94 Stegemann Thyssen Tailored Blanks with 1997 International Tailored blanks with straight weld seams
, Thomas; Stahl AG Nonlinear Weld Seams-- Body are now an accepted part of technical
Wonneber Properties and Engineering practice. In recent years, the welding
ger, Ingo; Production Conference facility technology developed by Thyssen
Mertens, and Stahl AG and Nothelfer GmbH has
Axel Exposition constantly been advancing, so that this
year alone four new welding plants could
start operating in Duisburg. The
introduction of this plant technology
ensures economic, qualitatively high-grade
series production of tailored blanks with
straight weld seams...
95 Stevens, General Automotive Laser 2000 Presentation 39 total
Mark W. Motors, Applications
Metal
Fabricating
Division
96 Stiles, General Laser Blank Welding, 1998 6th Annual 7 total
John Motors General Motors Global Automotive
Corporation, Perspective Laser
Metallic Applications
Worldwide Workshop
Purchasing 1998 (ALAW
'98)
Proceedings
97 Trogolo, J. IBIS Evaluation of Tailor 1998 Development
Michael; Associates, Welded Blanks Through s in Sheet
Diffenbach, Inc. Technical Cost Modeling Metal
Jeff R. Stamping
SAE Special
Publications

26
98 Uchihara, Sumitomo Performance of Mesh 1997 SAE Meeting pp. Formability, fatigue properties and
M.; Metal Seam Welds in Tailor Science 245- corrosion behavior of mash seam welded
Takahashi, Industries, Welded Blanks Lecture No. 248 steel sheets were investigated and the
J.; Kurita, Ltd. 974 results were compared with laser weld.
M.; Hirose, The stretch formability of mash seam weld
Y.; Fukui, and laser weld panels were the same level.
K. Mash seam weld however, showed slightly
smaller formability in hole expansion test...
99 van den Hoogovens Deep Drawing 1998 Proceedings pp. Tailored blanks are increasingly used in
Berg, A.C.; Research Simulation of Tailored 20th IDDRG 133- the automotive industry. A tailored blank
Meinders, and Blanks 144 consists of different metal parts, which are
T.; Development joined by a welding process. These metal
Stokman, ; University parts usually have different material
B. of Twente; properties. Hence, the main advantage of
Automotive using a tailored blank is to provide the right
Tailored material properties at specific parts of the
Blanks blank...
100 Van der OCAS Tailored Blanks: A Key 1996 Automotive pp. Steel is the material of choice for
Hoeven, J.- Technology for Light Automation 177- lightweight Body-in-White concepts. To
M; Weight Steel Auto Body Limited 185 meet new ecological requirements, the
Rubben, Structures global steel industry designed a new BIW
K.; concept, called the ULSAB (Ultra Light
Lambert, Steel Auto Body Structure), and set new
F.; De targets in weight, safety and structural
Rycke, I. performance...
101 Venkat, S.; Ohio State CO/2 Laser Beam 1997 Welding pp. Legislative and market pressures have
Albright, University Welding of Aluminum Journal 275.s- caused the automotive industry to consider
C.E.; 5754-0 and 6111-T4 282.s more fuel efficient designs of vehicles in
Ramasamy Alloys recent years.
, S.;
Hurley,
J.P.
102 Waddell, British Steel The Influence of the 1998 Society of pp. Tailor Welded Blanks (TWBs) can offer
W.; Strip Weld Structure on the Automotive 257- significant benefits in terms of weight
Jackson, Products; Formability of Laser Engineers 268 reduction, cost and performance. This
S.; University of Welded Tailored Blanks paper considers the influence of the laser
Wallach, Cambridge; weld on the formability of TWBs in a range
E.R. University of of steels with yield strengths from 15 MPa
Cambridge to 585 MPa...

27
103 Wadman, Institute of Research Programs on 1999 8 total
Boel Production Tailor Blank Formability
Engineering
Research
104 Walters, Laser Weld Process 1996 Laser pp. 1-
C.T.; Monitoring in Production Institute of 10
Ream, S.L. of Tailor-Welded Blanks America
Proceedings-
LIA
105 Watanabe, Mitsubishi Appearance of 1998 Welding pp. 21- This paper describes the appearance of
J; Heavy Measured Signals with International 28 the measured signals in response to
Nakabayas Industries Changes in Basic changes in the basic welding conditions.
i, T; Welding Conditions: The main results obtained are as follows:
Hiraga, H.; Features of Monitoring the average amplitude (V sub amp) of both
Inoue, T.; Methods for Laser the spectrum emission intensity and
Matsunawa Welding and Their plasma potential is far better correlated
, A. Application with the penetration depth than the
average output (Vsub ave)...
106 Watanabe, Mitsubishi Correlation Between 1998 Welding pp. 29- The authors are engaged in a research
J; Heavy Process Parameters International 38 program intended to clarify the behavior of
Nakabayas Industries and Measured Signals laser-induced plasma during laser welding
i, T; During Laser Welding of and to establish its applicability in
Hiraga, H.; Plates with Artificial monitoring laser welding parameters…
Inoue, T.; Defects: Features of
Matsunawa Monitoring Methods for
, A. Laser Welding and Their
Application
107 Watanabe, Mitsubishi Effect of Shielding Gas 1998 Welding pp. 9- The shielding gas used in laser welding
J; Heavy Plasma on Monitoring International 20 plays an important role in obtaining high-
Nakabayas Industries Signals in Laser quality welds. Argon shielding gas, being
i, T; Welding: Features of cheap to use, has most notably entered
Hiraga, H.; Monitoring Methods for widespread use, but it faces the growing
Inoue, T.; Laser Welding and problem of plasma generation in higher-
Matsunawa Their Application power laser welding...
, A.

28
108 Wild, Peter Department Project on Tailor Welded 1999 CAMM The first sponsored CAMM research
of Blanks (Centre for project is on "The Measurement of Weld
Mechanical Automotive Properties in Tailor Welded Blanks for
Engineering, Materials and Finite Element Modeling and Process
Queen's Manufacturin Control"…
University, g) Wed Page
McLaughlin
Hall
109 Wirth, Soudronic New Laser 2000 Automotive 12 total
Juerg Technologies for Laser Laser
Welded Tubes and Applications
Tailor Welded Blanks Workshop
2000
110 Wouters, User For an Optimized 1998 Proceedings pp. 89- The most usual and practical technique of
P.; Properties Combination of Steels 20th IDDRG 102 assembly is welding. The metallurgical
Monfort, Department, and Welding Processes and mechanical properties of the joint
G.; CRM Before Forming directly depend upon the thermal cycle
Defourny, imposed during welding. The weld has to
J. comply with the same requirements as the
parent materials namely formability and
strength properties...
111 Xie, Jian Edison Laser Lap Welding of 1999 7th Annual 9 total
Welding Galvanized Steel with Automotive
Institute No Gap Laser
Applications
Workshop
112 Yamasaki, NKK Effect of Chemical 1996 University of pp.
Y.; Composition, Miskolc 357-
Yoshida, Mechanical Properties 366
M.; and Thickness of Base
Kabasawa, Steels on Formability of
M.; Ono, Laser-Welded Blanks
M.

29
113 Thyssen Comparative 1998 Technische pp. 29- As distinguished from conventional tailor
Krupp Stahl; Considerations for Mitteilungen 35 welded blanks which are made with linear
Thyssen Design of Tailored weld lines that extend to the boundaries of
Fugetechnik Blanks and Thyssen the blanks, Thyssen engineered blanks
Engineered Blank have weld lines that can be curvilinear and
can provide thicker sheet sections in
patches. The production line for producing
engineered blanks by laser welding is
described...
114 Hydroformed Structural 1998 Automotive pp. Analyses indicate the influence of the
Elements: Economic Engineering 103- number of parts replaced and several other
Evaluation of the International 105 parameters in deciding whether stamping
Technology or hydroforming best suits a particular
process.
115 Project Will Develop 1998 Welding p. 22 Modular Vision Systems, Inc. (Vienna, VA,
Automated Laser Journal USA) will sell LaserVision joint tracking
Welding System for systems to Automated Welding Systems
Tailor Blank Production (Markham, Canada) for incorporation into
their laser automated tracking systems for
cutting and welding. The companies will
develop a fully automated laser welding
system for producing tailor welded blanks
for the car industry.
116 DCT Sells Blanks 1997 American …as a division of DCT since it was
Business to Noble Metal Market founded in 1990, sells most of its laser -
welded blanks to General Motors Corp.,
Chrysler Corp., Volkswagen de Mexico
S.A. and other automakers for…
117 Deep Drawing Tailor- 1997 Stamping pp. 26- Laser-welded blanks of AKDQ steel 279.4
Welded Blanks Journal 32 mm in diameter were deep drawn in a 160-
ton press to 152.4-mm-diameter cups
using a raw ratio of 1.83 with a view to
developing new design guidelines for the
deep drawing of tailor-welded blanks.
Computer simulations were also
performed...

30
118 Honda & Rover: To 1997 Automotive p. 13 Honda and Rover models will have laser-
Have Laser-Welded News Europe welded body panels in 1998, called tailor
Body Panels blanks. They are supplied by a joint
venture of French steelmaker Sollac and
UK-based Steel and Alloy Processing.
Tailored blank technology reduces weight
and costs…
119 Lasers Heating Up 1997 American p. 12A One example is tailor -welded blanks, and
Blank Market Metal Market within that category, laser-welded blanks.
A manufacturing process that began in
Germany in the early 1980s is now taking
off…
120 MVSI Subsidiary Wins 1997 PR Newswire p. 1009 …a fully automated laser welding system
Contract for Laser using MVS' laser vision technology for the
Vision Systems for Use production of tailor welded blanks for the
in Automated Welding automotive industry worldwide. Tailor
Systems for the welded blanks is an emerging technology
Automotive Industry used in the manufacturing of car door inner
panels, body door...
121 Olympic Steel, Inc. and 1997 PR Newswire p. 120 …plants in that region. It is expected to
the US Steel Group of employ approximately 25 persons at full
USX Corporation Form production. Laser welded blanks are used
Laser Welding Joint in the automotive industry for an increasing
Venture number of body fabrication applications.
Demand...
122 Usinor Seeks Share of 1997 Metal Bulletin …flat products subsidiary, Sollac and Steel
UK Autobody Market & Alloy (UK), steel processor, are planning
to build a laser welded blanks plant in the
UK with a 20k t/y welding line. The move
is an…
123 Shiloh Industries 1996 PR Newswire p. 125 …and aluminum coils into conventional
Announces Capital and welded blanks for the automotive
Improvements to industry, is upgrading its tailor welded
Provide for Growth blanking capabilities. The trends toward
Opportunities consolidation and outsourcing in the
automotive components industry are
presenting Shiloh…

31
124 Welding -- Electron and 1996
Laser-Beam Welded
Joints -- Guidance on
Quality Levels for
Imperfections; Part 1:
Steel
ISO This standard gives guidance on levels of
International imperfections in electron and laser beam
Standard welded joints in steel. Three levels are
13919-1 given in such a way as to permit
application for a wide range of welded
fabrications. The levels refer to production
quality and not to the fitness-for-purpose of
the product manufactured...
32