ThyssenKrupp Magazin

72 GALLARDO
An exquisite aluminum dress
The body is assembled part by part, being welded only if it is absolutely
necessary. This joining procedure is difficult with aluminum: for
one thing, the object always has to be placed in such a way that the
seam can be reached – which is why ThyssenKrupp Drauz has several
custom-made rotating devices to bring the different parts into the right
position. In addition, the excellent heat-conducting properties of the
light metal diffuse the strong heat that develops throughout the material,
causing it to stretch – and occasionally not return to its original
shape after it has cooled down. But this must not happen, given the tolerances
of one millimeter within the entire Gallardo frame and just twotenths
of a millimeter for visible parts, for example the gap between
door and frame. This is why the engineers have to consider aluminum’s
special material characteristics when determining how the parts will be
put together. Rivets, for example, do not produce heat distortion, and
so are used wherever possible; the same with screws – which is why the
Lamborghini Gallardo carries so many of them in invisible places. The
mechanic uses a manual device or other equipment to press the punch
rivets into the right combination to hold the material securely together;
a loud pop sound can be heard – the rivet is in place, and the next is
placed in the right spot. Many such pops create a wonderfully dotted
line, which makes for a high level of solidity.
The lower frame of the Lamborghini Gallardo is made first, either
welded or riveted, depending on the construction requirements. It
consists of three sections: front end and back end are attached to the
floor, in the step that makes it apparent to the human eye for the first
Luc Donckerwolke,
who designed the Gallardo
for Lamborghini, has
realized a vision by using corners,
edges and cuts to create
style combined with function:
robots and sensors ensure
that the car body shell
receives its ultimate shape.
TK Magazine | 1 | 2004 |