Are these factory welds?
12-07-2021, 10:47 AM
#5
AudiWorld Super User
they aren't welds, likely seam sealer for the points that are welded underneath - the cars are laser welded, so the actual welding bead is extremely tight
12-21-2021, 08:05 AM
#6
It is seam sealer. There are no welds on the strut tower.
The strut towers are cast aluminum and the surrounding panels are stamped steel. I don't know what Audi's specification is for connecting those panels, but typically it's both adhesive and mechanical fasteners.
As for welding, there is little, if any, factory steel seam welding. Steel unibody panels are almost always spot welded.
Probably the only place you'll see a seam weld on these cars is the suspension subframes.
The strut towers are cast aluminum and the surrounding panels are stamped steel. I don't know what Audi's specification is for connecting those panels, but typically it's both adhesive and mechanical fasteners.
As for welding, there is little, if any, factory steel seam welding. Steel unibody panels are almost always spot welded.
Probably the only place you'll see a seam weld on these cars is the suspension subframes.
Last edited by FrenchToast; 12-28-2021 at 08:42 AM.
12-27-2021, 08:43 AM
#8
AudiWorld Super User
Some chassis construction information on the type 8W is laid out on pages 8-11 of SSP 644. As noted, the strut tower is a single die-cast aluminum component.
Introduction:
The Audi A4 saloon and the Audi A4 Avant bodies have a hybrid design. This lightweight construction concept utilizes die-cast aluminium components in addition to regular sheet-metal parts. A decisive factor in modern body construction is the lightness and rigidty of the body structure as a whole. For this reason, the bodies of the Audi A4 incorporate die-cast aluminium components in addition to soft, high-strength, modern high-strength and ultra-high strength sheet-steel components (2 in the saloon and 4 in the Avant). These are the front spring strut mounts and the nodes at the upper end of the D posts on the Audi Avant A4. Thanks to geometrical lightweight construction and an intelligent material mix, the body of the Audi A4 is 15 kg lighter than that of the Audi A4 (type 8K).
The Audi A4 saloon and the Audi A4 Avant bodies have a hybrid design. This lightweight construction concept utilizes die-cast aluminium components in addition to regular sheet-metal parts. A decisive factor in modern body construction is the lightness and rigidty of the body structure as a whole. For this reason, the bodies of the Audi A4 incorporate die-cast aluminium components in addition to soft, high-strength, modern high-strength and ultra-high strength sheet-steel components (2 in the saloon and 4 in the Avant). These are the front spring strut mounts and the nodes at the upper end of the D posts on the Audi Avant A4. Thanks to geometrical lightweight construction and an intelligent material mix, the body of the Audi A4 is 15 kg lighter than that of the Audi A4 (type 8K).
Aluminium castings:
The aluminium castings in the vehicle structure are joined to the adjacent sheet-metal parts by punch riveting and using structural adhesive. The adhesive also serves to insulate both materials from one another, thus preventing contact corrosion. Specific repair solutions have been developed for repairing damage to these aluminium castings and adjoining sheet-steel parts. Straightening and reshaping work is not permitted in the area of these components.
The aluminium castings in the vehicle structure are joined to the adjacent sheet-metal parts by punch riveting and using structural adhesive. The adhesive also serves to insulate both materials from one another, thus preventing contact corrosion. Specific repair solutions have been developed for repairing damage to these aluminium castings and adjoining sheet-steel parts. Straightening and reshaping work is not permitted in the area of these components.
It is not permitted to perform any repair or reshaping work on the front of the Audi A4, because there is the danger that there may be cracks in the aluminum cast parts, which are not visible.
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