SSP_239_Audi A2 Body en.pdf

Service.

AUDI A2 - Body

Construction and Function

Self-study programme 239

For internal use only.

The Audi-Space-Frame ASF

in the A2

Audi A2 development targets

Measures

Weight savings of at least 40 % with respect

to a comparable steel body as a precondition

for a future 3-litre vehicle.

This is achieved with an aluminium Space-

Frame body design.

Using the full potential of lightweight

construction

This is made possible with the use of further

developed semi-ﬁnished aluminium products:

cast aluminium, extruded proﬁles and rolled

sheet metal.

SSP239_007

Economic production for the world’s ﬁrst

large-series production of aluminium vehicles

This is achieved with a construction that

allows a large degree of automation at the

raw body shell production stage.

Highest standards in terms of rigidity and crash response - “best in class”

Contents

Page

The material aluminium

Historical development at Audi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

The Audi-Space-Frame ASF

in the A2

Technological concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Overview of ASF

Bonding techniques

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Production methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Punch rivets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Internal high-pressure metal forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Metal inert gas welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Laser welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

OPEN SKY ROOF

Design and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Assembly work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Occupant protection . . . . . . . . . . . . . . . . . . . . . . 39

Repair concept . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Review of A8 aluminium technology

in the Audi A8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Repair concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

New

Attention

Note

The self-study programme will provide you with information on

construction and functions.

It is not intended as a workshop manual!

For maintenance and repairs please refer to the current technical

literature.

- A8 and A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ASF

The material aluminium

Historical development at Audi

Vehicle concepts

1999

Audi Space Frame A2

Audi A2

1994

Audi Space Frame A8

Audi A8

1991

Avus quattro study

1984

Early stage of the

Space-Frame technology

Audi 100 - aluminium sheet

metal vehicle

1913

Aluminium vehicle NSU 8/24

Long-distance saloon

completely made of aluminium

SSP239_008

Use of light metal alloys

Audi Space Frame

in the Audi A2

1999

A6 bonnet, wings and

back panel made of aluminium in

the A6 V8

TT bonnet

crankcase for the

1.8 l in the A6

1998

Crankcase for the

1.6 l in the A3/A4 Avant

A6 bonnet

Light alloy wheels as

standard

on the A4/A6/Cabrio

Door subframe

Audi A6

1997

Light alloy wheels as standard on the A3

Aluminium oil pan for the V6 petrol and TDI

1996

Audi Space Frame

ASF in the A8

Transver se

link

Audi A8

1994

Crankcase

4.2 l V8

1991

Door subframe

Audi 100

Side impact protection

Audi 100

1990

Crankcase

3.6 l V8

Dash panel cross piece in the

V8 made of magnesium

1988

Door subframe

Audi 80

1986

Door subframe

Audi 100

Bumper cross piece

for the Audi 100

Aluminium sheet

1982

SSP239_009

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