Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Process-Integrated Inspection for Ultrasound-Supported Friction Stir Welding of Metal Hybrid-Joints

27.09.2016

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.


X-ray image of a FSW seam

Fraunhofer IZFP

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.

Weitere Informationen:

http://www.izfp.fraunhofer.de/en.html

Sabine Poitevin-Burbes | Fraunhofer-Institut für Zerstörungsfreie Prüfverfahren IZFP

More articles from Machine Engineering:

nachricht PRESTO – Highly Dynamic Powerhouses
15.05.2017 | JULABO GmbH

nachricht Making lightweight construction suitable for series production
24.04.2017 | Laser Zentrum Hannover e.V.

All articles from Machine Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Can we see monkeys from space? Emerging technologies to map biodiversity

An international team of scientists has proposed a new multi-disciplinary approach in which an array of new technologies will allow us to map biodiversity and the risks that wildlife is facing at the scale of whole landscapes. The findings are published in Nature Ecology and Evolution. This international research is led by the Kunming Institute of Zoology from China, University of East Anglia, University of Leicester and the Leibniz Institute for Zoo and Wildlife Research.

Using a combination of satellite and ground data, the team proposes that it is now possible to map biodiversity with an accuracy that has not been previously...

Im Focus: Climate satellite: Tracking methane with robust laser technology

Heatwaves in the Arctic, longer periods of vegetation in Europe, severe floods in West Africa – starting in 2021, scientists want to explore the emissions of the greenhouse gas methane with the German-French satellite MERLIN. This is made possible by a new robust laser system of the Fraunhofer Institute for Laser Technology ILT in Aachen, which achieves unprecedented measurement accuracy.

Methane is primarily the result of the decomposition of organic matter. The gas has a 25 times greater warming potential than carbon dioxide, but is not as...

Im Focus: How protons move through a fuel cell

Hydrogen is regarded as the energy source of the future: It is produced with solar power and can be used to generate heat and electricity in fuel cells. Empa researchers have now succeeded in decoding the movement of hydrogen ions in crystals – a key step towards more efficient energy conversion in the hydrogen industry of tomorrow.

As charge carriers, electrons and ions play the leading role in electrochemical energy storage devices and converters such as batteries and fuel cells. Proton...

Im Focus: A unique data centre for cosmological simulations

Scientists from the Excellence Cluster Universe at the Ludwig-Maximilians-Universität Munich have establised "Cosmowebportal", a unique data centre for cosmological simulations located at the Leibniz Supercomputing Centre (LRZ) of the Bavarian Academy of Sciences. The complete results of a series of large hydrodynamical cosmological simulations are available, with data volumes typically exceeding several hundred terabytes. Scientists worldwide can interactively explore these complex simulations via a web interface and directly access the results.

With current telescopes, scientists can observe our Universe’s galaxies and galaxy clusters and their distribution along an invisible cosmic web. From the...

Im Focus: Scientists develop molecular thermometer for contactless measurement using infrared light

Temperature measurements possible even on the smallest scale / Molecular ruby for use in material sciences, biology, and medicine

Chemists at Johannes Gutenberg University Mainz (JGU) in cooperation with researchers of the German Federal Institute for Materials Research and Testing (BAM)...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Plants are networkers

19.06.2017 | Event News

Digital Survival Training for Executives

13.06.2017 | Event News

Global Learning Council Summit 2017

13.06.2017 | Event News

 
Latest News

Quantum thermometer or optical refrigerator?

23.06.2017 | Physics and Astronomy

A 100-year-old physics problem has been solved at EPFL

23.06.2017 | Physics and Astronomy

Equipping form with function

23.06.2017 | Information Technology

VideoLinks
B2B-VideoLinks
More VideoLinks >>>