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The Audi Space Frame ASF in the A2 Audi A2 development targets Measures Weight savings of at least 40 with respect This is achieved with an aluminium Space to a comparable steel body as a precondition Frame body design. for a future 3 litre vehicle. 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 This is achieved with a construction that large series production of aluminium vehicles 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” 2 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 A8 and A2 . 16 Components 18 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 ASF 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. 3 The material aluminium Historical development at Audi Vehicle concepts 1999 Audi Space Frame A2 1999 Audi A2 1994 Audi Space Frame A8 1994 Audi A8 1991 1991 Avus quattro study 1984 Early stage of the 1984 Space Frame technology Audi 100 aluminium sheet metal vehicle 1913 1913 Aluminium vehicle NSU 8/24