**BYU and Toyota Revolutionize Welding Technique for Aluminum Minivan Doors**

An innovative collaboration is pushing the boundaries of automotive manufacturing efficiency. Engineers from Brigham Young University (BYU) and Toyota have jointly developed a cutting-edge welding technique tailored for aluminum sliding doors on the Toyota Sienna minivan. This new method, known as refill friction stir spot welding, promises significant advancements in both strength and sustainability.

Refill friction stir spot welding is designed to replace the traditional resistance spot welding technique, which is usually employed for steel components. By adapting the process for aluminum, the method uses 40 times less energy and yields welds that are 10 times stronger, according to a BYU release. This move comes as the automotive industry increasingly shifts towards lighter aluminum parts to enhance vehicle performance and fuel efficiency.

The collaboration arose after BYU manufacturing engineering professor Yuri Hovanski showcased the innovative welding process at a conference. Toyota engineers, impressed by the technique, proposed a partnership. Hovanski, alongside graduate student Damon Gale, later visited Toyota’s manufacturing plant in Indiana to evaluate the current production methods and integrate the new process for 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,” said Hovanski. This side-by-side comparison of vehicles fabricated with both traditional and new welding technologies provided valuable insights.

The new welding process works by joining metal without melting it. Instead, pressure is applied, and a pin is inserted into the metal. The friction from the pin softens the metal, allowing the two aluminum sheets to be stirred together. Once the pressure is released, the hole fills in, creating a robust joint with fewer spot welds than conventional methods.

This technique not only enhances the quality of welds but also reduces consumable materials since no additional filler is required. “Ultimately, we are looking for ways to do things more efficiently, greener and cleaner,” Hovanski emphasized. He and his students have published their findings in the SAE International and Journal of Manufacturing and Materials Processing, advocating for this to become the new standard in automotive manufacturing.

"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.

With this innovative approach, BYU and Toyota are not only advancing manufacturing techniques but also taking significant steps toward environmental stewardship and sustainability in the automotive industry.