The manufacturing functional feasibility of implementing Friction Stir Welding (FSW) for automobile chassis fabrication is discussed using a case study. In the case study, the Design for Manufacturing (DFM) principles are applied to manufacture an aluminum automobile chassis. Various DFM issues are addressed while proposing the FSW technique as an alternative to laser welding and metal inert gas welding techniques. DFM guidelines involving joint design change, component geometries, and component elimination are discussed in this paper. By making appropriate changes in the component geometries and joint designs and eliminating some components, more than 50% of the joints in the example case study could be welded using the FSW technique.

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