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Laser welding of tailored blanks

A tailored blank is a flat sheet made from two pieces of metal, placed - in the case of laser welding - side by side and butt welded. After welding, blanks are formed into components such as door panels, engine rails and sunroof reinforcements. Tailored blanks have the potential for significant cost saving in the automotive industry.

The two pieces of material from which the tailored blank is made may be dissimilar, for example, coated and uncoated steel. This would be the case when a component needs enhanced corrosion protection in a certain region. Or the two pieces may be of different thickness, allowing designers to select and strengthen critical areas of the body without adding significant weight. Thick/thin tailored blanks may also be used in impact energy absorption areas to achieve controlled collapse in an accident.

Laser welds are suited to tailored blank production as they are very narrow, have no raised top- or under-bead and do not require special finishing. TWI has developed procedures for laser butt welding tailored blanks and application of the technique to body component manufacture. 

Benefits of tailored blanks include:

  • ~ Reduced material usage and scrap - increases in material yield of between 25-40% have been claimed.

  • ~ Components of different shape and thickness can be produced with properties tailored to performance requirements. Overall manufacturing costs can be reduced by eliminating up to 80% of pressing operations.

Cost-efficient matching of body component materials to meet service requirements and achieve weight reduction. In a coated steel side-member panel, weight reductions of up to 10% can be achieved compared with pressed and resistance welded assemblies.

Please email contactus@twi.co.uk for further information

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