CTMA Investment - $250K; Industry Cost Share - $500K Spaceframes are the preferred body structure for military vehicles due to their light weight and strength. Cost and quality issues with conventional MIG and TiG joining methods for thin-walled components used in spaceframes have prevented their use. Deformation Resistance Welding (DRW), a new solid state joining method that does not melt the materials to be joined reduces manufacturing cost by a factor of 10 while increasing dimensional accuracy, corrosion resistance, and weld cycle time. Total vehicle weight reductions of 10% are achieved while improving survivability, cost, and versatility. CTMA Investment - $250K; Industry Cost Share - $500K Corrosion Resistant Solid State Thin-Walled Component Joining Novel solid state welding technique especially useful lightweighting ground vehicle platforms using spaceframe body architectures DoD Benefits Level 1 Benefits: Allows the use of bolt-on non-structural armors that can be upgraded throughout the life of the vehicle. Same vehicle structure can be easily reconfigured depending on mission and service requirements (canvas to Frag-7). Dramatic fuel and maintenance savings can be realized when operating HMMWV at canvas level of protection (7,000 lbs gwv) in non-threat environments vs. Frag 7 (13,500 lbs.). Provides HMMWV rollover protection in unarmored configuration. Level 2/3 Benefits: Widespread deployment of lightweighting spaceframes on both new and legacy ground weapon systems will produce weight savings of 10% and operational versatility while maintaining performance and safety. Application by Armed Services: CTMA Sponsored: U. S. Marine Corps/ U.S. Army/TARDEC: Design depot installed retrofit spaceframe component capable to support a FRAG 7 armor kit and blast shield for the M1151 HMMWV platform. Modeling report of component/total vehicle performance under various loading conditions. 1500 lbs weight savings utilizing improved frame design with FRAG 7 equivalent bolt on armor kit options. Manufacturing tooling designed and fabricated for welding of physical sub-frame component using DRW method. Test parts from prototype tooling demonstrating DRW welds that meet performance specifications