Ever faster, ever lighter, ever increasing energy efficiency: Lightweight construction is one of the key technologies of today’s industrial production. By now, saving of weight, material and energy applies across industries while taking account of the entire product life cycle. In this manner the realization of innovative lightweight structures as well as the combination of dissimilar materials play an essential and mandatory role to meet the divergent requirements, components are expected to fulfill. Hence joining technologies are of crucial importance for any kind of goal-driven lightweight construction.
Fraunhofer IZFP researchers aim for process-integrated inspection of the error-prone seam zones of friction stir welded components. In doing so, they significantly contribute to the reduction of costs and wastage at concurrent saving of time.
As a novel, forward-looking joining technology, Friction Stir Welding (FSW) is an easily applicable, clean and innovative process especially suited for light metals and increasingly applied in automotive industry, machine construction and aerospace engineering. Unlike most conventional joining techniques it enables considerable weight saving, thus complies the goals of lightweight construction.
In order to extend existing application limits, a variant of FSW called “Ultrasound-Supported Friction Stir Welding” (US-FSW) was developed. To guarantee a steadily high quality of weld seams and to identify possible process fluctuations, the application of nondestructive inspection methods is indispensable for both variants: Quality has to be ensured during all phases of the process and defects or imperfections with possibly negative impact on the weld seam durability – such as pores and cracks – have to be detected.
Concerning nondestructive testing (NDT), FSW is subject to similar principles as conventional welding procedures. The application of high-performance, reliable and cost-efficient NDT to assess the quality of the produced joints enables a considerable extension of FSW’s application range.
“The spectrum of procedures provided at Fraunhofer IZFP allows to obtain a holistic view of the entire process. This goes much further than typical ways of inspection such as the post-process detection of irregularities. Our approach enables to increase efficiency even before and during the welding operation and to monitor the joining process. As a consequence we find greatly widened fields of application for FSW,“ Dr. Benjamin Straß, group leader within Fraunhofer IZFP’s “Production-integrated NDT” department, explains.
The research project is funded by the German Research Foundation DFG. Within the scope of this project, Fraunhofer IZFP‘ researchers develop methods to optimize process parameters, to detect possible defects in the joining area and to characterize alterations of the material properties of friction stir welded hybrid-joints.
“To our institute, such a fundamental research project offers the incentive to test and to develop new approaches which partially can be transferred to further production technologies. By this, new potential clientele can be attracted. Even beyond the boundaries of this project there is a regular communication and exchange of experiences between the research institutions in the priority program*. Hereby, new and interesting contacts arise regularly,“ Straß concludes.
Sabine Poitevin-Burbes | Fraunhofer-Institut für Zerstörungsfreie Prüfverfahren IZFP
Scientists from Hannover develop a novel lightweight production process
27.09.2017 | IPH - Institut für Integrierte Produktion Hannover gGmbH
PRESTO – Highly Dynamic Powerhouses
15.05.2017 | JULABO GmbH
Salmonellae are dangerous pathogens that enter the body via contaminated food and can cause severe infections. But these bacteria are also known to target...
University of Maryland researchers contribute to historic detection of gravitational waves and light created by event
On August 17, 2017, at 12:41:04 UTC, scientists made the first direct observation of a merger between two neutron stars--the dense, collapsed cores that remain...
Seven new papers describe the first-ever detection of light from a gravitational wave source. The event, caused by two neutron stars colliding and merging together, was dubbed GW170817 because it sent ripples through space-time that reached Earth on 2017 August 17. Around the world, hundreds of excited astronomers mobilized quickly and were able to observe the event using numerous telescopes, providing a wealth of new data.
Previous detections of gravitational waves have all involved the merger of two black holes, a feat that won the 2017 Nobel Prize in Physics earlier this month....
Material defects in end products can quickly result in failures in many areas of industry, and have a massive impact on the safe use of their products. This is why, in the field of quality assurance, intelligent, nondestructive sensor systems play a key role. They allow testing components and parts in a rapid and cost-efficient manner without destroying the actual product or changing its surface. Experts from the Fraunhofer IZFP in Saarbrücken will be presenting two exhibits at the Blechexpo in Stuttgart from 7–10 November 2017 that allow fast, reliable, and automated characterization of materials and detection of defects (Hall 5, Booth 5306).
When quality testing uses time-consuming destructive test methods, it can result in enormous costs due to damaging or destroying the products. And given that...
Using a new cooling technique MPQ scientists succeed at observing collisions in a dense beam of cold and slow dipolar molecules.
How do chemical reactions proceed at extremely low temperatures? The answer requires the investigation of molecular samples that are cold, dense, and slow at...
23.10.2017 | Event News
17.10.2017 | Event News
10.10.2017 | Event News
24.10.2017 | Physics and Astronomy
24.10.2017 | Physics and Astronomy
24.10.2017 | Life Sciences