Graphic + video, detailed explanation of the whole process of Tesla all-aluminum body production
According to relevant data analysis: if the vehicle weight is reduced by 10%, the fuel efficiency can be increased by 6% to 8%; for every 100kg reduction in the vehicle weight, the fuel consumption per 100 kilometers can be reduced by 0.3 to 0.6 liters. Replacing traditional steel with aluminum to make cars can reduce vehicle weight by 30 to 40 percent.
The entire Model S developed and manufactured by Tesla contains 250 patents. Its all-aluminum body takes into account the characteristics of light weight and high strength. In addition to the body, most of the front and rear suspension materials are also made of aluminum. From a manufacturing standpoint, the way this car is produced is fundamentally different from other cars. Through the following real production video of Tesla factory, you will learn more about the production process of Model S from raw material selection, stamping, welding, painting to final assembly!
Since aluminum alloy materials are sensitive to heat, if the traditional welding process is used, there will be a problem that the strength of the material will decrease, and because it is easily deformed by heat, the dimensional accuracy of the all-aluminum body is not easy to control. So, how did the Tesla factory overcome the difficulties of the aluminum alloy welding process?
Tesla welding workshop detailed video:
The welding process of Tesla factory is CMT cold metal transfer technology and DeltaSpot resistance spot welding technology.
In 2005, Austrian Fronius launched CMT (Cold metal Transfer) cold metal transfer technology, which realized the connection of steel and aluminum for the first time in the world. Compared with traditional MIG/MAG welding, CMT process is “cold transfer”. “. The DeltaSpot resistance spot welding process is a new technology developed for aluminum welding. It has extremely high process reliability, and each resistance welding spot can achieve 100% repeatability: the base metal and the electrode are protected by the electrode strip, and the electrode strip The movement between the electrode and the base metal to be joined enables a continuous welding process, ensuring a constant level of quality over multiple shifts.
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