Joining techniques for lightweight

constructions in TBI
Public Results
Project partners

TBI = Trucks &Trailers, Buses, Industrial, Agricultural, Recreational & Special Vehicles

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Project purpose
Acquiring knowledge of joining techniques for constructing vehicles
using lightweight materials

Methodology/Project phases
1. Application screening  5 case studies + requirements

2. Screening + selection of lightweight materials and joining techniques

3. Experimental research  testing of selected materials and joining techniques

4. Toolkit  composing a practical handbook and related database with data and
results

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Application screening
5 generic case studies

Joining sandwich materials with frame structures

structure of bodywork of market vehicle, floors of motor caravan, bottom of chassis, floor of
boot area of motor coaches, floor of passenger area in buses and cars

Joining sandwich materials with one another

walls of motor caravan, ceiling of motor caravan, interior/furniture, interior finishing of
market vehicle

Joining of materials with different coefficients of expansion

side/boot panels of motor coaches, body panels

Joining heavily stressed hybrid structures

chassis of market vehicle, self-levelling frame, covers of grain tank, joining of side panels of
bus with chassis

Joining techniques for lightweight alternatives for glass

partitions in police vehicles, partitions in buses

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Study
Screening of materials based on application requirements

Traditional Lightweight
Plywood Sandwich Materials

710kg/m³ 200kg/m³

Hard glass Transparant plastics

2600 kg/m³
1250 kg/m³

Metal body panel FR Polymers /Blend Polymers

7800 kg/m3 1400 kg/m3

Structural Steel High-tensile steel in trailer chassis

: ≈ 2.4 tonnes : ≈ 1.5 tonnes

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Study
Screening of joining techniques based on applied materials and application
requirements
Adhesive bonding Welding and soldering
Glues and structural tapes techniques

Screwed joints, riveted joints

Combination of joining
techniques

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Study
Selection of joining techniques based on applied materials and application
requirements

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Experimental research
Testing of selected materials and joining techniques

Joining sandwich materials with frame structures

1. Testing of joint  Lap Shear Test according to DIN EN 1465

At sample level – comparing glues and tapes

> 12 glues
> 7 structural tapes
3 types of sandwich materials
2 types of frames
> 260 samples

2. Testing on a floor construction  HALT – Dynamic test

Accelerated lifecycle test on floor panels

2 glues
2 tapes
6 combinations

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Experimental research
Testing of selected materials and joining techniques

Joining sandwich materials with one another

1. Strength of self-constructed sandwich panels  use of lightweight sandwich structures in

interior construction

• 3 different sandwich structures

• strength and displacement: F-s diagram
• observing behaviour upon failure

2. Semi-static test – moment force on T-joint with sandwich wallapplicability of a wide

range of techniques for joints in sandwich structures

• 17 techniques + variants
• strength and displacement: F-s diagram
• observing behaviour upon failure

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Experimental research
Testing of selected materials and joining techniques

Joining of materials with different coefficients of expansion

Assessing the effect of thermal stress (30° C <> 70° C) on the following material
combinations using different glues and glue thicknesses

Structure Body
Steel Alu
Steel Pultrusion
Steel ABS
Steel ABS/PC
Alu Pultrusion
Alu ABS
Alu ABS/PC

 Measuring of deformation at different temperatures: Structured White Light Scanning

3D-image of deformation - 3D colour plot

3D-displacements (X-Y-Z) + visual representation

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Experimental research
Testing of selected materials and joining techniques

Heavily stressed hybrid structures

Examining the potential of high-tensile steel in combination with structural steel in chassis
constructions

Gaining of experience with structural riveted joints: comparing them with welded or bolted joints

 Accelerated lifecycle test at sample level

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Experimental research
Testing of selected materials and joining techniques

Joining techniques for transparent materials, lightweight alternatives for glass

1. Static pressure test until joint fails  establishing the adhesive force and behaviour upon
failure of different types of tape

 5 adhesive tapes
 2 transparant plastics

2. Simulating the impact of a human body using a test object according to NBN EN 12600 =
shock resistance test

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Experimental research
Handbook/Survey of joining techniques for lightweight constructions for the
TBI industry

Properties Comparison Table Properties

Test reports Supplier contact list

Lightweight Materials

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 For more information:

PaROD&DPSHVWULQL
Project leader JoinTBI
tel. +32 11 790 5
paRODFDPSHVWULQL@flandersdrive.be

www.flandersdrive.be

Confidential - ©2011 Flanders’ DRIVE all rights reserved