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  • kaMeL: Development of innovative, digitally supported and climate-friendly technology concepts for joining overlap-free longitudinal and unilaterally accessible transverse joints during fuselage assembly
    kaMel will connected digital technologies for the efficient and resource-saving fuselage assembly.
    The main work packages are (i) resource-efficient data management, (ii) innovative material joining processes for fuselage structures, and (iii) highly flexible automation systems for the positioning, sealing and joining of (iv) large assemblies. Hereon will be repsonsible for Joining of longitudinal seam of fuselage structure via solid-state joining processes by using variants of bobbin-tool friction stir welding with focus on tool development and tolerance management.
    Project coordinator: Airbus
    Duration: 01.08.2023 – 31.07.2026
  • Stir4Steel: Friction stir welding for improving joinability of high-performance steels for automotive components to boost green road mobility
    Stir4Steel will provide efficient, environmental-friendly, and cost-effective methodologies to join advanced-high strength (AHSS), press hardening steels (PHS) and enhanced machinability steels, as well as these steels in combination with Al casts or extrusions. It will enable multi-material designs for battery trays, shock towers/front rails, B-pillars and monoblock pistons, leading to weight-optimized components, energy efficiency and lower CO2 footprint. Led by a tip-of-the-spear consortium consisting of steel producers, car manufacturers, FSW joining technologists, and innovation experts, Stir4Steel aims to pave the way for more sustainable applications and higher penetration of advanced steel grades in the automotive as well as aviation, trains, and shipbuilding sectors.
    Project coordinator: Stirtec
    Duration: 01.09.2021 – 31.08.2024

  • LESSMAT: Lightweight construction system for passenger trains and cruise ships by increasing material utilization and efficiency in production The project is part of the funding line "CO2 saving and CO2 binding through the use of new construction techniques and materials". The manifold CO2 saving potentials start with the raw materials used, focus on energy consumption during long-term operation and end with disposal at the end of the product life cycle. The project aims to use lightweight construction measures to improve the products of rail vehicle and shipbuilding industries while maintaining value creation in Germany. Both OEMs are at the forefront of technology in their industries, and it is expected that significant advantages can be achieved through the exchange and concrete application and adaptation of established processes in the other industry. Here, the high adaptability of construction and design to different project requirements required in rail vehicle construction is mentioned, which can enable further optimization in shipbuilding and at the same time allows the space for the partial replacement of traditional design rules. On the other hand, the partly automated differential construction method is established in shipbuilding, which can contribute to a cost reduction in rail vehicle construction.
    Project coordinator: Siemens Mobility
    Duration: 01.06.2021 – 31.05.2024
  • AVaiL: Automotive methods and autonomous processes for metallic aerospace components
    The overall objective of the project is the further development and optimization of three solid-state joining processes, friction stir welding (FSW), friction spot welding (RPS), and friction surfacing welding (RPS), to achieve an efficient and cost-effective production of components and assemblies while at the same time increasing structural safety through improved damage tolerance behavior. For this purpose, process-microstructure-property relationships are systematically determined for the three processes, which lead to high-quality joining properties with the shortest possible cycle times. With the development of these joining processes and their introduction in the production of components and assemblies, a weight reduction of 20% and a reduction in production time of 20% should be achieved compared to conventional mechanical fastening technologies. The knowledge gained in the initial phase of the project will be used in the final phase to realize representative examples of integral structures such as a door environment (assemblies), a sickle bulkhead, seat rails and bulkhead structures.
    Project coordinator: Premium Aerotec GmbH
    Duration: 01.08.2020 – 30.04.2024

  • DAHLIAS: Development and Application of Hybrid Joining in Lightweight Integral Aircraft Structures
    Automated welding processes to assemble aircraft structures using standard high strength non-weldable aluminum alloys could allow strengthening of the global leadership and competitiveness of the European aeronautics industry against low-cost and manual manufacturing industries of emerging countries. In this project, such a joining technology – the refill friction stir spot welding process (Refill FSSW) – applied to standard high strength aluminum alloys, will be investigated to optimize the manufacturing of fairly complex aircraft structures such as fuselage sections. Friction-based processes could lead to benefits when compared to the traditional riveted structures. They produce welded joints without flaws or defects and superior mechanical properties. Furthermore, the heat input and residual stress are comparatively low. The adoption of this welding process provides weight and costs savings of about 15%. Moreover, assembly time and cost will also be reduced due to fewer assembly operations.
    The DAHLIAS project aims at closing the knowledge gaps regarding the systematic development of a new production technology (Refill FSSW) coupled with a new adhesive sealant (hybrid joining) and the respective questions when applying this technology in industrially produced aircraft structures, such as quality control, process monitoring and damage tolerance behavior. These aims fulfil and compliment the challenges identified in the call (Optimization of hybrid joining (Refill FSSW and adhesive bond) for increasing mechanical properties and corrosion protection of the joints) with additional topics leading to the industrialization of this technology, i.e. elevation of the present TRL (currently app. TRL5 to TRL6).
    Duration: 1.10.2018 – 30.09.2021
    Participants: Helmholtz Zentrum Hereon (Coordinator), Institut de Soudure, Belgisch Instituut voor Lastechniek VZW, Chemetall GmbH, Tra-C Industrie SAS