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