A recent episode of Sandy Munro’s Tesla Model Y teardown series has revealed that the electric car company utilized friction stir welding (FSW) for the crossover’s thermal management system. The welding technique is commonly used among aerospace companies, like SpaceX, as a way to maintain the strength of aluminum parts while securing a reliable bond between pieces.
Munro’s analysis of the Octovalve coolant system revealed Tesla’s techniques for the revised thermal management portion of the Model Y. Munro discovered the Octovalve on April 4 after digging into the Model Y’s internal build. The new coolant assembly seemed to be a revised version of the Model 3’s “Superbottle,” which served as the heart of the sedan’s thermal management system.
A car’s thermal management apparatus is responsible for controlling and maintaining proper temperatures in critical portions of the vehicle. In the case of the Model Y, the Octovalve is responsible for motor, battery, and cabin cooling, according to Munro. The Detroit auto veteran said that typically, these systems should not be cooling the cabin if they are controlling battery or motor temperature. The thermal management system in the Model Y seems to be controlling the cabin, the battery, the electronics, and the motor nonetheless.
The Octovalve seems to be a state-of-the-art system as it uses, “some clever little ball valves that open and close to make sure that everything’s getting heated or everything’s being cooled to where it needs to be,” Munro said.
With the assembly overlooking the temperature for these many parts of the vehicle, the system is subjected to drastic and sharp temperature changes. Over time, the difference between heat and cold can begin to weaken portions of the car part, especially if it was exposed to excessive temperatures during manufacturing. This is where some SpaceX-grade solutions come into play.
Tesla chose to utilize friction stir welding for its aluminum portions of the coolant assembly. “This is a cool way of putting two parts of aluminum together, some other materials as well, but aluminum is kind of the most suited for it. And in essence, what happens is you have a stylus that spins around very very quickly. It pokes through the two pieces of metal that you want to friction stir weld. Then, it goes around the outside edge, and what it does is it uses the plastic state or thixotropic state of the aluminum to bind it together,” Munro said.
Simply put, the process allows aluminum to reach a temperature that allows two pieces of metal to come together with a strong bond, but it never turns the metal into a soft, liquid-like state. “It’s like soft butter, butter that you could see is firm, but you could cut it with a knife.”
The advantage of using this process is that the heat from the welding process only applies to the outer edges of the metal. The additional material that is not bonded to anything does not see the heat and is not weakened by the welding process. Stir welding is also time effective as it can be completed in a short period, but it is a careful process that does not apply unneeded stress upon the rest of the assembly.
SpaceX uses friction stir welding for its rockets, as it increases strength by exposing only the bonded portions of two pieces of metal to each other. Friction stir welding was used by SpaceX back in 2008 when the company was combining barrel sections of the Falcon 9’s second stage. “The FSW joins metal without flames, sparking, inert gasses, or fumes, and produces a far superior weld in aluminum-lithium alloys as compared to traditional methods,” SpaceX said in a news update.
In the spirit of humor, Tesla and Elon Musk saw the Octovalve as a perfect opportunity to not only improve the performance of the vehicle temperature regulation system but also as an appropriate time to sprinkle in some additional humor in the form of an Easter Egg. The Model 3 donned a cape-wearing bottle-figured superhero for its “Superbottle” system, while the Model Y includes a snowflake-stamped Octopus as an Easter Egg.
Tesla has increased the effectiveness of its thermal management with the introduction of the Model Y’s Octovalve system. Elon Musk stated that it was some of the best engineering he had ever seen. The welding process could increase the longevity of the machine through its lack of exposure to excessive heat and stress during manufacturing.
Watch Munro’s video on the Model Y’s Octovalve welding below.
News
Tesla adjusts Robotaxi safety monitor strategy in Austin with new service area
The positioning of the driver, as well as the driver’s hands being closer to the steering wheel, is more similar to what Tesla is doing in the Bay Area Robotaxi program than it is to what it has done in Austin.
Tesla has adjusted its Robotaxi safety monitor strategy in Austin after it expanded its service area in the city last week for the third time.
Tesla has been operating its Robotaxi platform in Austin since June 22. The vehicles have been operated without a driver, but Tesla has placed safety monitors in the passenger’s seat as a precaution.
The safety monitors are responsible for performing any necessary interventions and maintaining a safe and comfortable cabin for riders as they experience Tesla’s first venture into the driverless ride-sharing space.
Last week, Tesla expanded its service area in Austin for the third time, expanding it from about 90 square miles to 170 square miles. The expansion included new territory, including the Austin-Bergstrom International Airport, Tesla’s Gigafactory Texas, and several freeways.
Tesla Robotaxi geofence expansion enters Plaid Mode and includes a surprise
The freeway is an area that is uncharted territory for the Tesla Robotaxi program, and this fact alone encouraged Tesla to switch up its safety monitor positioning for the time being.
For now, they will be riding in the driver’s seat when routes require freeway travel:
Sept 1 in Austin and our Robotaxi arrived with Tesla safety driver in the driver seat, similar to the Bay area (no logo on the car). Here’s that first moment when I realized, our autonomous car was heading onto the freeway. pic.twitter.com/1QfyN2Ubzf
— Gail 🇺🇸 (@gailalfaratx) September 2, 2025
The positioning of the driver, as well as the driver’s hands being closer to the steering wheel, is more similar to what Tesla is doing in the Bay Area Robotaxi program than it is to what it has done in Austin.
This is sure to draw criticism from skeptics, but it is simply a step to keep things controlled and safe while the first Robotaxi drives take passengers on the highway with this version of the Full Self-Driving software.
This FSD version differs from the one that customers have in their own vehicles, but CEO Elon Musk has indicated something big is coming soon. FSD v14 is coming to vehicles in the near future, and Musk has said its performance is pretty incredible.
Tesla’s Elon Musk shares optimistic teaser about FSD V14: “Feels sentient”
News
Tesla has best month ever in Turkey with drastic spike in sales
Tesla managed to sell 8,730 Model Y vehicles in Turkey, outpacing almost every competitor by a substantial margin. Only one brand sold better than Tesla in August in Turkey, and it was Renault.
Tesla had its best monthly performance ever in Turkey in August, thanks to a drastic spike in sales.
Tesla saw an 86 percent bump in sales of the new Model Y in Turkey in August compared to July, dominating the market.
The performance was one of Tesla’s best in the market, and the company’s sales for the month accounted for half of all EV sales in Turkey for August, as it dominated and led BYD, which was the second-best-selling brand with just 1,639 units sold.
Tesla managed to sell 8,730 Model Y vehicles in Turkey, outpacing almost every competitor by a substantial margin. Only one brand sold better than Tesla in August in Turkey, and it was Renault.
Turkey reported 8,730 Tesla sales and 10.6% market share in August. BEV penetration is 21.3% and Tesla has 49.9% of this segment. 🇹🇷
• Market share is 558 basis points or 111% above the 3-month trailing average of 5.0%
• Tesla second best-selling brand
• Model Y best-selling… pic.twitter.com/qLhX7VQWXp— Roland Pircher (@piloly) September 2, 2025
Electric vehicles are, in some ways, more desirable than their gas counterparts in Turkey for several reasons. Most of the reasoning is financial.
First, EVs are subject to a lower Special Consumption Tax in Turkey. EVs can range from 25 percent to up to 170 percent, but this is less than the 70 to 220 percent rate that gas-powered vehicles can face. The tax is dependent on engine size.
Additionally, EVs are exempt from the annual Motor Vehicle Tax for the first ten years, providing consumers with a long-term ownership advantage. There are also credits that can amount to $30,000 in breaks, which makes them more accessible and brings down the cost of ownership.
Let’s not forget the other advantages that are felt regardless of country: cheaper fuel costs, reduced maintenance, and improved performance.
The base Model Y is the only configuration available in Turkey currently.
News
Tesla is upgrading airbag safety through a crazy software update
“This upgrade builds upon your vehicle’s superior crash protection by now using Tesla Vision to help offer some of the most cutting-edge airbag performance in the event of a frontal crash.”
Tesla is upgrading airbag safety through a crazy software update, which will utilize the company’s vision-first approach to enable better protection in the event of an accident.
Over the years, Tesla has gained an incredible reputation for prioritizing safety in its vehicles, with crash test ratings at the forefront of its engineers’ minds.
This has led to Tesla gaining numerous five-star safety ratings and awards related to safety. It is not just a statistical thing, either. In the real world, we’ve seen Teslas demonstrate some impressive examples of crash safety.
Everything from that glass roof not caving in when a tree falls on it to a Model Y surviving a drive off a cliff has been recorded.
However, Tesla is always looking to improve safety, and unlike most companies, it does not need a physical hardware update to do so. It can enhance features such as crash response and airbag performance through Over-the-Air software updates, which download automatically to the vehicle.
In Tesla’s 2025.32 Software Update, the company is rolling out a Frontal Airbag System Enhancement, which aims to use Tesla Vision, the company’s camera-based approach to self-driving, to keep occupants safe.
The release notes state (via NotaTeslaApp):
“This upgrade builds upon your vehicle’s superior crash protection by now using Tesla Vision to help offer some of the most cutting-edge airbag performance in the event of a frontal crash. Building on top of regulatory and industry crash testing, this release enables front airbags to begin to inflate and restrain occupants earlier, in a way that only Tesla’s integrated systems are capable of doing, making your car safer over time.”
The use of cameras to predict a better time to restrain occupants with seatbelts and inflate airbags prior to a collision is a fantastic way to prevent injuries and limit harm done to those in the vehicle.
The feature is currently limited to the Model Y.
Tesla adjusts Robotaxi safety monitor strategy in Austin with new service area
Tesla has best month ever in Turkey with drastic spike in sales
Tesla is upgrading airbag safety through a crazy software update
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