Development of the engine cradle design, one of the chassis fatigues parts, with aluminum extrusion method and investigation of weldability

, In this thesis, R&D activities were be presented/shared knowledge the electric vehicle for one of the Germany-based vehicle manufacturer company for the M2 class steel engine cradle about converting to new aluminum extrusion design. At the end of the development workflow, the new extruded aluminum engine cradle prototype was evaluated/performed by vehicle manufacturing company.The new aluminum design of the engine cradle's 3D modeling was created on the CATIA platform considering the first mounting locations and package volume of the target steel engine cradle. After that static analysis ran to the aluminum design with HyperWorks software, and coupon-based welding studies applied through using to CMT Robot. As a result, 43.76 % weight reduction was achieved. All, customer engineering and requirements were also provided. The thesis was funded and successfully completed in 2019-2020 under the Project Number 3181441 by the TÜBİTAK 1501 Industrial R&D Projects Support Program.