KSL+

BYU, Toyota develop new welding technique for minivan doors

Nov 3, 2024, 1:37 PM

Engineers at Brigham Young University and the Japanese vehicle-manufacturing giant Toyota. (Jaren W...

Engineers at Brigham Young University and the Japanese vehicle-manufacturing giant Toyota. (Jaren Wilkey, BYU Photo)

(Jaren Wilkey, BYU Photo)

PROVO — An unlikely partnership is developing the future of minivans: engineers at Brigham Young University and the Japanese vehicle-manufacturing giant Toyota.

BYU partnered with Toyota to develop a more efficient welding method for the sliding doors on the Toyota Sienna.

The current welding technique — resistance spot welding — is designed for steel. The new process, refill friction stir spot welding, is based on the same fundamental principles but tweaked and specialized for aluminum’s unique chemical properties.

The new technique is more relevant than ever as car manufacturers focus on utilizing lighter aluminum parts rather than steel. It uses 40 times less energy, emits fewer emissions, and produces welds that are 10 times stronger, a release from BYU said.

BYU manufacturing engineering professor Yuri Hovanski showcased the welding innovation at a conference where the Toyota team saw him and suggested a partnership. Hovanski and graduate student Damon Gale visited Toyota’s manufacturing plant in Indiana to evaluate current production and analyze how to use the new process in aluminum sliding doors.

“Toyota has been using the cleanest technologies they have available to them, but what BYU research is bringing to them is a technology that is a game changer,” Hovanski said. “They partnered with us to be able to essentially do a side-by-side comparison of the same model of car with new welding technology.”

Refill friction stir spot welding joins metal together without melting it, resulting in the metal remaining in a solid state. Pressure is applied, then a pin is inserted into the metal where it is softened by friction.

The two sheets of aluminum are then stirred together with a tool and when the pressure is released, the hole fills in. This creates a strong-quality joint that requires fewer spot welds than typical joints in a vehicle.

“Ultimately, we are looking for ways to do things more efficiently, greener and cleaner,” Hovanski said.

The process cuts down on consumables because no filler material is required and less equipment is used.

“It is super exciting to demonstrate that what we’re working on is helping the environment. Ultimately, as engineers, we believe in trying to be good stewards of the planet,” Hovanski said.

Hovanski and his students published papers with their findings in the SAE International and Journal of Manufacturing and Materials Processing

“Our research concludes that refill friction stir spot welding is a preferable method for joining aluminum body panels and is positioned to become the new standard in automotive manufacturing,” said Gale, who was the first author of the SAE International paper.

KSL 5 TV Live

KSL+

U.S. Army soldiers in Joint Base Elmendorf-Richardson, Alaska, Oct. 15. The Department of Veterans ...

Collin Leonard, KSL.com

VA funding first psychedelic-assisted therapy study since the 1960s

The U.S. Department of Veterans Affairs is planning to study the effects of a psychedelic drug on veterans as the regulatory landscape behind psychedelic treatment shifts.

2 days ago

Dry eyes, viral conjunctivitis—also known as pink eye—and eye allergies are common in the winte...

MICHELLE LEE

Protecting your eyes in the winter

Did you know that our eyes need extra special care during the winter? It may not be top of mind for most people, but winter weather can take a toll on our eye health.

2 days ago

Singer-songwriter Taylor Swift performs during her Eras Tour in Melbourne, Australia, on Feb. 16. S...

Carter Williams, KSL.com

Salt Lake City’s top music artists in 2024, according to Spotify

Taylor Swift wrote a thousand songs that Salt Lakers apparently found cool in 2024, according to newly released Spotify data.

4 days ago

West Valley City leaders approved plans paving the way for redevelopment of the Redwood Swap Meet s...

Tim Vandenack, KSL.com

Redwood Swap Meet vendors out by Dec. 22 as redevelopment edges ahead

Vendors at the Redwood Swap Meet have to vacate the site by late December to make way for planned new housing.

9 days ago

Anya Fazulyanov, 19, from Cedar Hills, poses with her trophy from the Food Network's Christmas Cook...

Ivy Farguheson, KSL.com

Cedar Hills woman wins Food Network’s ‘Christmas Cookie Challenge’

Anya Fazulyanov did not have to be intimidated by the older, possibly more experienced competition on the Food Network's "Christmas Cookie Challenge." They needed to be intimidated by her.

12 days ago

Christmas lights at Temple Square in Salt Lake City are pictured on Nov. 21. The Church of Jesus Ch...

Carter Williams, KSL.com

Temple Square’s Christmas lights are back. Here’s what to expect this season

Temple Square remains under construction as crews continue to renovate the Salt Lake Temple and remodel the downtown area around it, but visitors will have more room to roam around its holiday display this year.

12 days ago

Sponsored Articles

2 computer techs in a computer shop holding up a computer server with the "hang loose" sign...

PC Laptops

Choosing the Right Computer: A Comprehensive Guide

With these tips, choosing the right computer that fits your needs and your budget will be easier than ever.

crowds of people in a German style Christmas market...

This Is The Place Heritage Park

Celebrate Christkindlmarket at This Is The Place Heritage Park!

The Christkindlmarket is an annual holiday celebration influenced by German traditions and generous giving.

Image of pretty woman walking in snowy mountains. Portrait of female wearing warm winter earmuff, r...

Lighting Design

Brighten your mood this winter with these lighting tricks

Read our lighting tips on how to brighten your mood in the winter if you are experiencing seasonal affective disorder.

A kitchen with a washer and dryer and a refrigerator...

Appliance Man

Appliance Man: A Trusted Name in Utah’s Home Appliance Industry

Despite many recent closures of local appliance stores, Appliance Man remains Utah's trusted home appliance business and is here to stay.

abstract vector digital social network technology background...

Les Olson

Protecting yourself against social engineering attacks

Learn more about the common types of social engineering to protect your online or offline assets from an attack.

family having fun at home...

Lighting Design

Discover the impact of lighting on your mood

From color temperature to lighting saturation, we tackle how different lighting design setups can impact your day-to-day mood.

BYU, Toyota develop new welding technique for minivan doors