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Honda Develops New Technology to Join Steel and Aluminum to reduce vehicle weight


Version française Car Engineer

Door PanelHonda Motor Co., Ltd. today announced that it has newly developed a technology to join steel and aluminum and applied it to enable adoption of aluminum for an outer door panel, which has conventionally been made of steel. Honda will adopt this technology first to the North American version of the all-new Acura RLX, which will go on sale in the United States in March 2013, and will expand application sequentially to other models.

To join together the dissimilar metals of steel and aluminum, the simultaneous establishment of several different technologies was required such as technologies to prevent corrosion (electrical corrosion) and thermal deformation caused by the different expansion rates of steel and aluminum.

Honda newly developed three technologies that enabled adoption of aluminum for the outer door panel.

  • Technology to join dissimilar materials: adoption of “3D Lock Seam” structure, where the steel panel and aluminum panel are layered and hemmed together twice. 
Honda 3D Lock Seam Technology
  • Technology to prevent electrical corrosion: adoption of highly anticorrosive steel for the inner panel and a new form that assures the complete filling of the gap with adhesive agent.
Technology to prevent electrical corrosion
  • Technology to control thermal deformation: adoption of adhesive agent with low elastic modulus and optimized position of the 3D Lock Seam.

The new technology contributes to the improvement of fuel economy and dynamic performance of the vehicle by reducing door panel weight by approximately 17% compared to the conventional all-steel door panel. In addition, weight reduction at the outer side of the vehicle body enables to concentrate the point of gravity toward the center of the vehicle, contributing to improved stability in vehicle maneuvering.

Charlie’s opinion:

All innovations allowing to reduce vehicle mass are welcomed today. It is good to see that the desire to reduce fuel consumption allows to raise innovations and to develop new technologies in all technical areas of automotive engineering.

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