Forschung für den Mittelstand - Die IGF-Projektdatenbank

Werkzeuge für das Rührreibschweißen von Stählen

The demand for lightweight components for the automotive and aerospace industries is increasing, as they can be used to achieve fuel savings and meet climate targets. In order to respond to the increasing demand, manufacturing processes must be optimized so that targeted weight reductions can also be realized on load-bearing components. Friction stir welding (FSW) offers great potential for this, as this joining technique can be used to weld sheets of different material thicknesses in a robust, environmentally friendly and cost-efficient manner. Thus, an individual reduction of wall thicknesses at less stressed areas is easily possible and new doors for lightweight construction are opened. The main objective of the CeraWeld project is to develop a wear-resistant ceramic tool with optimized geometry to be applied in the FSW process for joining high-strength steels. CeraWeld is divided into two subprojects, which are carried out simultaneously in Germany and Brazil. The aim of the subproject under German leadership is the development of innovative ceramic materials and the simulation-based optimization of the tool geometry. The Brazilian subproject will determine ideal process parameters for FSW of high-strength steels by ceramic tools, do investigations of in-situ quality monitoring and test the performance of the tools based on various aspects. Validation of the results will be carried out in a relevant production environment with a common demonstrator. The binational work will be complementary and will foster fruitful business relationships between all project participants. Finally, CeraWeld holds great potential for securing and creating jobs in SMEs that use lightweight construction. Not only the 12 members of the user committee, but also other SMEs along this value chain will benefit from the results, which will be widely disseminated during and after project implementation.