Audi TT (2007 year). Manual — part 258
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
9
The aluminium sheet shown here exhibits severe
contact corrosion, which has resulted in mechanical
failure of the punch riveted joint.
This illustration shows clearly what effects contact
corrosion can have if adequate corrosion protection
is not provided. A this joint, the flange was sealed in
the bodyshell without using adhesive.
In this case, the aluminium sheet showed no dam-
age due to contact corrosion after exposure to iden-
tical environmental conditions.
By way of a comparison, this illustration shows the
same flange with an adhesive bond and sealing.
383_007
Seal
Seal
383_008
Seal
Adhesive
Seal
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
10
Audi Space Frame of the Audi TT
Comparison of ASF concepts
Audi A8 (2003
➔
)
383_013
Aluminium castings
Sheet aluminium parts
Aluminium extruded sections
383_014
Sill section Audi A8
Three-chamber extruded section
383_017
A-post, Audi A8
Single-chamber extruded section
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
11
Audi TT (2006
➔
)
383_009
Sheet aluminium parts
Aluminium extruded sections
Sheet-steel parts
Aluminium castings
383_015
A-post, Audi TT
Sheet-aluminium sections (interior/exterior)
383_016
Sill section, Audi TT
Four-chamber extruded section
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
12
Joining techniques and production processes
383_018
Riveted joint
Overview
In addition to well-known processes such as MIG welding or punch riveting, the joining techniques of Flow
Drill screwing and Kerb-taper riveting are used for the first time on the Audi TT.
In the production process, a laser cleaning method is used for cleaning before the roof drip moulding is
attached by welding.
383_019
Flow-Drill screw connection
383_020
Clean Laser
Technology
Process
Quantity per vehicle
Mechanical
joining techniques
Punch riveting
Flow Drill screwing
Solid punch riveting (Kerb-Konus)
Clinching
1615 pce.
229 pce.
96 pce.
164 pce.
Thermal
joining techniques
MIG welding
Laser welding
Resistance spot welding
MAG welding
Stud welding
21462 mm
5309 mm
1287 spots
809 mm
234 pce.
Bonding technology
Bonding
97156 mm
Machining technology
Milling
Drilling
Thread cutting
Brushing
Roll seaming
Clean lasering
188 mm
16 pce.
8 pce.
2300 mm
26737 mm
4000 mm
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