Cadillac will use what it claims are the auto industry’s most comprehensive and advanced mixed material manufacturing techniques to build its new CT6 top line sedan.
The CT6, on sale in the fourth quarter of 2015, will be built at the Detroit-Hamtramck Assembly plant, using a unique combination of joining techniques, a first for any General Motors’ model. A new body shop with new tooling and technology – including 205 robots – has been added to the plant. The fully automated, roughly 138,000 sq ft shop is dedicated to the sedan.
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When it launches, the CT6 will expand the Cadillac range upwards – adding rather than replacing a current product. Positioned above today’s CTS and XTS product lines, the CT6 aims to join the elite group of top-class large luxury cars.
“For the Cadillac CT6 we have developed additional new body construction techniques and technologies allowing various types of advanced and lightweight materials to be combined within the manufacturing environment like never before,” Cadillac president Johan de Nysschen said at the Washington auto show.
“We have invested US$300m in the Detroit-Hamtramck Assembly plant to make this possible,” he said. “These actions will allow us to advance the art of manufacturing and take craftsmanship and manufacturing technology to a new level.”
Combining different types of joining methods, engineers overcame previous manufacturing difficulties involving the joining of traditionally dissimilar materials, while still optimising every panel for its desired purpose.
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By GlobalDataMaterial joining techniques prominent in the body construction of the CT6 include patented aluminium spot welding technology, aluminium laser welding, which creates a seamless joining of exterior panels, self piercing rivets, which are able to join different types of materials together with a clean appearance and flow drill screws, which are able to join different types or materials and used in conjunction with adhesive.
Aluminium arc welding and structural adhesive are also separately used for CT6 body assembly.
Among the five techniques, engineers chose the best joining method depending on material combination and body location (for machine equipment access).
To weld both the inner and outer vehicle frames, 28 robots descend on the vehicle body in two separate framing stations, joining the body in white together from all angles. The robots are mounted above and beside the vehicle and can also reach beneath it. The two framing processes were choreographed to compensate for different microscopic vibrations and body construction resembles an orchestra as the robotic arms move in and out around the vehicle.
“Never before has an automaker brought this combination of joining techniques together for a single vehicle,” said Travis Hester, CT6 executive chief engineer. “The manufacturing team has enabled body engineers to optimise the vehicle for mass, safety, stiffness and materials with more precision than ever.”
“The result is a top-level large luxury sedan, with class-leading body stiffness that generates excellent driving characteristics and impressive fuel efficiency without compromises to safety, comfort or quality,” he said.
Once the body construction is complete, a large robotic arm lifts the entire vehicle from one part of the assembly line to an upper level conveyer – unheard of for a vehicle the size of CT6 – to be transferred across the plant.
