Audi Space Frame and multi-material construction
The Space Frame concept puts aluminum extrusions and vacuum die-cast nodes where the loads are and hangs the panels off that. Repairing it means knowing which node may be replaced, where an extrusion may be sectioned and where it may not, which joints are riveted and bonded versus welded, and what the factory permits at all — Audi restricts a good deal of it, and the restrictions exist because the structure's crash behavior depends on those joints performing exactly as designed.
Aluminum work is done in a separated area with dedicated tooling. Steel particles that land on aluminum embed in the softer metal and set off galvanic corrosion that shows up as blistering under the paint a year or two later, by which point nobody connects it to the repair. Rivets are single-use, adhesive is applied within its specified open time and allowed to cure, and every dissimilar-metal interface gets the specified corrosion protection.
Everything structural is measured in three dimensions against Audi's specification before work starts, corrected with anchored sequential pulls, and re-measured until it reads within tolerance. You get the before-and-after printout.
- —Separated aluminum area with dedicated tooling and consumables
- —ASF joints riveted, bonded, and welded only where permitted
- —Three-dimensional structural measuring, before and after
- —Boron steel replaced rather than heat-straightened
- —High-voltage shutdown procedure on e-tron models
- —quattro driveline geometry verified after structural work
