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Int J Mater Form (2010) Vol. 3 Suppl 1:1059–1062 DOI 10.1007/s12289-010-0953-3 © Springer-Verlag France 2010 DEVELOPMENT OF A MECHANICAL JOINING PROCESS FOR AUTOMOTIVE BODY-IN-WHITE PRODUCTION 1* 2 1 1 1 Stephan Busse , Marion Merklein , Karl Roll , Michael Ruther , Michael Zürn 1 Daimler AG – Materials and Process Engineering 2 University of Erlangen – Chair of Manufacturing Technology ABSTRACT: The current lightweight design is realized by the multi-material mix in body-in-white production of automotive industry. In car bodies, the proportion of high-strength steels and aluminum alloys increases. Therefore, it is necessary to join these materials. Mechanical joining processes are suitable for a multi-material mix. But in combination with high-strength steels, only processes with additional elements, like rivets, are useful. The development of a new clinching technology shows a solution for an economical method for joining these different materials. An innovative single-stage process without any additional joining elements is created to extend the current limits of mechanical joining technologies. This makes it possible to join aluminium alloys and high-strength steel by punching and clinching in one step. Using the special material behavior of the parts to be joined is most important for this mechanical joining process. A clinching sequence, a scheme and a gradual analysis support the understanding of this joining method. Some examples of connected material combinations complete this description. Further steps to improve this joining proc