AUDI AG Neckarsulm Lightweight aluminum structures with
“Vorsprung durch Technik”

Production of the Audi A8 involves lightweight aluminum construction. This is a demanding process that necessitates the perfect connection of numerous ground studs, where the quality of each stud weld is highly dependent on the cleanliness of the surface. In the case of aluminum sheets less than 2 millimeters thick (such as those used in the production of the A8), cleaning with „Clean Flash“ by the stud welding machine itself is no longer practical. The heat input would be too great and the sheets would burn through during the welding process. Furthermore, this method can result in pores which impair the seam quality.

To assure the required quality, in the past Audi had to have complete parts chemically cleaned. Prior to the construction of a new production plant in 2017, this expensive process was outsourced to suppliers. Up to that point, no cost-effective alternatives existed that were compatible with series production and compliant with the quality requirements.