Tailored Blank Weld Layout for Fracture-Controlled Structural Members

The patent applies local quality by removing aluminum plating only from specific high-stress regions (flange sections) rather than the entire welded surface. The crash analysis identifies that aluminum plating removal is necessary only in regions where tensile forces concentrate during collision, such as flange sections. In other regions like side wall portions where stress is lower, the aluminum plating is retained to maintain corrosion protection and structural integrity, thereby reducing overall processing time while maintaining weld strength where it matters most.

The patent reduces tool wear and extends tool life by limiting aluminum plating removal to only the necessary high-stress flange sections. Since the removal process involves mechanical or chemical treatment that wears down tools, applying it to a smaller, targeted area rather than the entire welded surface significantly reduces the cumulative wear on removal tools while still achieving the required weld strength in critical regions.

The patent uses crash analysis to create a virtual model or analytical representation of the structural member's stress distribution during collision. This digital copy or model allows identification of high-stress regions without physically testing multiple prototypes. The crash analysis model replicates collision scenarios and reveals where tensile forces concentrate, enabling optimized aluminum plating removal decisions based on simulated data rather than extensive physical experimentation.