The integration of experiments with numerical simulations can efficiently support a quick evaluation of the welded joint. In this work, the MIG welding operation on aluminum T-joint thin plate has been studied by the integration of both simulation and experiments. The aim of the paper is to enlarge the global database, to promote the use of thin aluminum sheets in automotive body industries and to provide new data. Since the welding of aluminum thin plates is difficult to control due to high speed of the heat source and high heat flows during heating and cooling, a simulation model could be considered an effective design tool to predict the real phenomena. This integrated approach enables new evaluation possibilities on MIG-welded thin aluminum T-joints, as correspondence between the extension of the microstructural zones and the simulation parameters, material hardness, transient 3D temperature distribution on the surface and inside the material, stresses, strains, and deformations. The results of the mechanical simulations are comparable with the experimental measurements along the welding path, especially considering the variability of the process. The results could well predict the welding-induced distortion, which together with local heating during welding must be anticipated and subsequently minimized and counterbalance

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Fixture systems have a great importance in modern manufacturing and assembly because of the high number of scenarios in which they are used. Fixture design is a complex task since the system effectiveness depends both on position and type of locators. Several authors deal with the problem of determine the most suitable design for fixture systems but their investigation is commonly limited to the evaluation of the effects due to the locators position. In the present work a design method is proposed to evaluate the fixture systems considering also the locators type. Since it is possible to model the fixtures as multi-performance systems, the comparison is performed by introducing appropriate sensitivity indexes. The effectiveness of the design method is proved through the application to an automotive case study.