Friction Stir Welding
Assembly Line
Honda Outlines Key Production Processes Behind New Line of EVs
Honda 0 Series is the automaker’s new approach to electric vehicle development, which is focusing on the theme of “thin, light and wise.” The goal of the R&D project is to minimize battery size while providing sufficient cruising range and a nimble driving experience that transcends the existing image of EVs.
Honda engineers are focusing their efforts on four core production technologies, including megacasting and friction stir welding. Megacasting involves molding large cast parts such as one-piece battery enclosures that eliminate seams. A new battery case, which traditionally consists of more than 60 parts, has been reduced to only five parts, making it possible to produce a high-quality, thin and light enclosure.
3D Friction Stir Welding (FSW) is being applied to two processes in the manufacturing of battery cases. The first is the process of joining parts made by megacasting to form the case enclosure, and the second is the process of joining the water jacket cover, which is necessary to provide the battery with cooling. The technology uses only the frictional heat between the rotating rod-shaped tool and the joint to soften and join the aluminum parts.