A Review of Advanced Joinery Methods for Lightweight Automotive Applications

Muyang He; Xinyue Ye; Dihao Zhang; Ruizhe Cai; Qi Lan; Weihao Zhao

doi:10.54254/2755-2721/2026.KA27515

Applied and Computational EngineeringOpen access

A Review of Advanced Joinery Methods for Lightweight Automotive Applications

Research Article

Open Access

A Review of Advanced Joinery Methods for Lightweight Automotive Applications

Muyang He ^1* Xinyue Ye ², Dihao Zhang ³, Ruizhe Cai ⁴, Qi Lan ⁵, Weihao Zhao ⁶

¹ Shenzhen College of International Education

² Shanghai University of Engineering Science

³ University of California

⁴ Nanjing Foreign Language School

⁵ Shenzhen Longcheng High School

⁶ Changwai Bilingual School

^*Corresponding author: s23085.he@stu.scie.com.cn

Published on 2 October 2025

ACE Vol.188

ISSN (Print): 2755-273X

ISSN (Online): 2755-2721

ISBN (Print): 978-1-80590-397-0

ISBN (Online): 978-1-80590-398-7

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Abstract

To enhance fuel economy and minimize emissions of vehicles, a lightweight design is currently considered the most viable option by the automotive industry. This paper will investigate mechanical joints and welded joints that connect different lightweight materials for assembly. An analysis has been conducted on multiple modern joint technologies, such as bolted joints, friction stir welding, MIG welding, laser welding, ultrasonic welding, and riveting. By using a machine to test the strength in tensile and shear, it was found that MIG welding has the highest strength in the welding field, with an endurance strength of 238.3 MPa. These findings are meant to furnish engineers with ideas on how to optimize the strength-to-weight ratio of assemblies with multiple materials in vehicles, as these will promote the manufacture of lightweight, well-balanced, and energy-efficient vehicles.

Keywords:

Tensile Shear Strength, Lightweight Automotive Design, Advanced Joinery Methods

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