Friction Stir Welding APM Vehicle Body Structures: INNOVIA APM 300 Case Study

Abstract

Bombardier's INNOVIA APM 300 body structure has been designed to meet the structural requirements of ASCE 21 Automated People Mover Standards - Part 2. The body structure consists of an aluminum roof, floor, and side wall panels. The roof and floor panels consist of aluminum extrusions continuously joined by the Friction Stir Welding (FSW). The FSW process has many benefits in joining aluminum; however, it was difficult to quantify these advantages using existing analysis methodology and design standards. This paper: 1. Discusses the criteria applied to FSW joints based on existing design standards (ASCE 21, Aluminum Association Design Manual); 2. Compares Innovia APM 300 floor and roof panels to previous APM designs; 3. Discusses the benefits of the FSW process as applied to the Innovia APM 300 design using Bombardier's experience along with academic research and industry consensus; and 4. Explores how the maturation of FSW standards and design criteria could increase margins of safety for the Innovia APM 300 design and result in more efficient body structure designs in the future.