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
Waymo scrutinized after self-driving taxis cause traffic jams during SF blackout
It’s not farfetched to speculate that it would have been a doomsday scenario for Tesla had FSD behaved this way.
A power outage across San Francisco over the weekend forced numerous Waymo self-driving taxis to stop at darkened intersections and cause traffic blockages in multiple locations across the city. The disruption left riders stranded, frustrated drivers blocked, and city officials stepping in as the Alphabet-owned company temporarily suspended service amid the widespread gridlock.
Needless to say, it would likely have been a doomsday scenario for Tesla had FSD behaved in a similar way, especially if fleets of its robotaxis blocked traffic for numerous drivers.
Power outage halts Waymo fleet
The outage knocked out electricity for tens of thousands of customers, leaving traffic signals dark across large parts of the city, as noted in a report from the New York Times. Waymo vehicles began stopping at intersections and remained stationary for extended periods, seemingly unable to operate. Tow truck operators worked through the night removing immobilized vehicles, while videos circulated online showing Waymos with hazard lights flashing as traffic backed up around them.
Waymo later confirmed that it had paused its Bay Area ride-hailing service after the San Francisco mayor’s office contacted the company about the congestion its vehicles were contributing to. Service began coming back online shortly after 3:30 p.m. local time, though some users still reported being unable to request rides. Waymo maintained that no injuries or accidents were reported during the outage.
Autonomous cars during emergencies
The incident surprised industry observers since autonomous vehicles are designed to function during signal outages and temporary connectivity losses. Waymo stated that its vehicles treat nonfunctional signals as four-way stops, but “the sheer scale of the outage led to instances where vehicles remained stationary longer than usual to confirm the state of the affected intersections. This contributed to traffic friction during the height of the congestion.” Experts suggested the problem may have been linked to the vehicles’ reliance on remote assistance teams, which help resolve complex situations the cars cannot handle independently.
“Yesterday’s power outage was a widespread event that caused gridlock across San Francisco, with non-functioning traffic signals and transit disruptions. While the failure of the utility infrastructure was significant, we are committed to ensuring our technology adjusts to traffic flow during such events,” the Waymo spokesperson stated, adding that it is “focused on rapidly integrating the lessons learned from this event, and are committed to earning and maintaining the trust of the communities we serve every day.”
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Tesla aims to combat common Full Self-Driving problem with new patent
Tesla writes in the patent that its autonomous and semi-autonomous vehicles are heavily reliant on camera systems to navigate and interact with their environment.
Tesla is aiming to combat a common Full Self-Driving problem with a new patent.
One issue with Tesla’s vision-based approach is that sunlight glare can become a troublesome element of everyday travel. Full Self-Driving is certainly an amazing technology, but there are still things Tesla is aiming to figure out with its development.
Unfortunately, it is extremely difficult to get around this issue, and even humans need ways to combat it when they’re driving, as we commonly use sunglasses or sun visors to give us better visibility.
Cameras obviously do not have these ways to fight sunglare, but a new patent Tesla recently had published aims to fight this through a “glare shield.”
Tesla writes in the patent that its autonomous and semi-autonomous vehicles are heavily reliant on camera systems to navigate and interact with their environment.
The ability to see surroundings is crucial for accurate performance, and glare is one element of interference that has yet to be confronted.
Tesla described the patent, which will utilize “a textured surface composed of an array of micro-cones, or cone-shaped formations, which serve to scatter incident light in various directions, thereby reducing glare and improving camera vision.”
The patent was first spotted by Not a Tesla App.
The design of the micro-cones is the first element of the puzzle to fight the excess glare. The patent says they are “optimized in size, angle, and orientation to minimize Total Hemispherical Reflectance (THR) and reflection penalty, enhancing the camera’s ability to accurately interpret visual data.”
Additionally, there is an electromechanical system for dynamic orientation adjustment, which will allow the micro-cones to move based on the angle of external light sources.
This is not the only thing Tesla is mulling to resolve issues with sunlight glare, as it has also worked on two other ways to combat the problem. One thing the company has discussed is a direct photon count.
CEO Elon Musk said during the Q2 Earnings Call:
“We use an approach which is direct photon count. When you see a processed image, so the image that goes from the sort of photon counter — the silicon photon counter — that then goes through a digital signal processor or image signal processor, that’s normally what happens. And then the image that you see looks all washed out, because if you point the camera at the sun, the post-processing of the photon counting washes things out.”
Future Hardware iterations, like Hardware 5 and Hardware 6, could also integrate better solutions for the sunglare issue, such as neutral density filters or heated lenses, aiming to solve glare more effectively.
Elon Musk
Delaware Supreme Court reinstates Elon Musk’s 2018 Tesla CEO pay package
The unanimous decision criticized the prior total rescission as “improper and inequitable,” arguing that it left Musk uncompensated for six years of transformative leadership at Tesla.
The Delaware Supreme Court has overturned a lower court ruling, reinstating Elon Musk’s 2018 compensation package originally valued at $56 billion but now worth approximately $139 billion due to Tesla’s soaring stock price.
The unanimous decision criticized the prior total rescission as “improper and inequitable,” arguing that it left Musk uncompensated for six years of transformative leadership at Tesla. Musk quickly celebrated the outcome on X, stating that he felt “vindicated.” He also shared his gratitude to TSLA shareholders.
Delaware Supreme Court makes a decision
In a 49-page ruling Friday, the Delaware Supreme Court reversed Chancellor Kathaleen McCormick’s 2024 decision that voided the 2018 package over alleged board conflicts and inadequate shareholder disclosures. The high court acknowledged varying views on liability but agreed rescission was excessive, stating it “leaves Musk uncompensated for his time and efforts over a period of six years.”
The 2018 plan granted Musk options on about 304 million shares upon hitting aggressive milestones, all of which were achieved ahead of time. Shareholders overwhelmingly approved it initially in 2018 and ratified it once again in 2024 after the Delaware lower court struck it down. The case against Musk’s 2018 pay package was filed by plaintiff Richard Tornetta, who held just nine shares when the compensation plan was approved.
A hard-fought victory
As noted in a Reuters report, Tesla’s win avoids a potential $26 billion earnings hit from replacing the award at current prices. Tesla, now Texas-incorporated, had hedged with interim plans, including a November 2025 shareholder-approved package potentially worth $878 billion tied to Robotaxi and Optimus goals and other extremely aggressive operational milestones.
The saga surrounding Elon Musk’s 2018 pay package ultimately damaged Delaware’s corporate appeal, prompting a number of high-profile firms, such as Dropbox, Roblox, Trade Desk, and Coinbase, to follow Tesla’s exodus out of the state. What added more fuel to the issue was the fact that Tornetta’s legal team, following the lower court’s 2024 decision, demanded a fee request of more than $5.1 billion worth of TSLA stock, which was equal to an hourly rate of over $200,000.
Delaware Supreme Court Elon Musk 2018 Pay Package by Simon Alvarez
Waymo scrutinized after self-driving taxis cause traffic jams during SF blackout
Tesla aims to combat common Full Self-Driving problem with new patent
