Friction Joining - Low Energy Manufacturing for Hybrid Structures in Fuel Efficient Transport Applications
Lead Research Organisation:
University of Manchester
Department Name: Materials
Abstract
There are clear drivers in the transport industry towards lower fuel consumption and CO2 emissions through the introduction of designs involving combinations of different material classes, such as steel, titanium, magnesium and aluminium alloys, metal sheet and castings, and laminates in more efficient hybrid structures. The future direction of the transport industry will thus undoubtedly be based on multi-material solutions. This shift in design philosophy is already past the embryonic stage, with the introduction of aluminium front end steel body shells (BMW 5 series) and the integration of aluminium sheet and magnesium high pressure die castings in aluminium car bodies (e.g. Jaguar XK).Such material combinations are currently joined by fasteners, which are expensive and inefficient, as they are very difficult to weld by conventional technologies like electrical resistance spot, MIG arc, and laser welding. New advanced solid state friction based welding techniques can potentially overcome many of the issues associated with joining dissimilar material combinations, as they lower the overall heat input and do not melt the materials. This greatly reduces the tendency for poor bond strengths, due to interfacial reaction and solidification cracking, as well as damage to thermally sensitive materials like laminates and aluminium alloys used in automotive bodies, which are designed to harden during paint baking. Friction joining techniques are also far more efficient, resulting in energy savings of > 90% relative to resistance spot and laser welding, are more robust processes, and can be readily used in combination with adhesive bonding.This project, in close collaboration with industry (e.g. Jaguar - Land Rover, Airbus, Corus, Meridian, Novelis, TWI, Sonobond) will investigate materials and process issues associated with optimising friction joining of hybrid, more mass efficient structures, focusing on; Friction Stir, Friction Stir Spot, and High Power Ultrasonic Spot welding. The work will be underpinned by novel approaches to developing models of these exciting new processes and detailed analysis and modelling of key material interactions, such as interfacial bonding / reaction and weld microstructure formation.
Organisations
- University of Manchester (Lead Research Organisation)
- Jaguar Land Rover Automotive PLC (Collaboration)
- Novelis Global Research and Technology Center (Collaboration)
- Airbus (United Kingdom) (Project Partner)
- Novelis (Canada) (Project Partner)
- Meridian Lightweight Technologies UK Ltd (Project Partner)
- Sonobond (Project Partner)
- Tata Steel (United Kingdom) (Project Partner)
- Tata Motors (United Kingdom) (Project Partner)
Publications
Tsivoulas D
(2012)
Interactions between zirconium and manganese dispersoid-forming elements on their combined addition in Al-Cu-Li alloys
in Acta Materialia
Rodgers B
(2016)
Quantification of the influence of increased pre-stretching on microstructure-strength relationships in the Al-Cu-Li alloy AA2195
in Acta Materialia
Tsivoulas D
(2014)
The effect of Mn and Zr dispersoid-forming additions on recrystallization resistance in Al-Cu-Li AA2198 sheet
in Acta Materialia
Chen Y
(2012)
HAZ development and accelerated post-weld natural ageing in ultrasonic spot welding aluminium 6111-T4 automotive sheet
in Acta Materialia
Chan C
(2010)
Analysis of the Homogeneity of Particle Refinement in Friction Stir Processing Al-Si Alloys
in Advanced Materials Research
Awang Draup A
(2022)
Modelling of friction stir welded AA2139 aluminium alloy panels in tension and blast
in International Journal of Impact Engineering
Panteli A
(2012)
Optimization of Aluminium-to-Magnesium Ultrasonic Spot Welding
in JOM
Jedrasiak P
(2014)
Modeling of the Thermal Field in Dissimilar Alloy Ultrasonic Welding
in Journal of Materials Engineering and Performance
Jedrasiak P
(2016)
Thermal Modeling of Al-Al and Al-Steel Friction Stir Spot Welding
in Journal of Materials Engineering and Performance
Description | Systematic research was carried out on the targeted processes, of the material flow, defect formation, and bonding mechanisms, using advanced characterisation techniques like 3D micro-tomography. The results were compared to process models developed in parallel by Cambridge University. The work gave a new insight into the welding processes and revealed that, when applied to dissimilar materials, they did not behave as had been previously expected, which led to poorer performance and delayed weld formation. In particular, the longer time required to form optimum joint strengths caused more extensive intermetallic reaction than anticipated and gave too long a process cycle for industrial application. Reaction was found to occur much faster in welding than in static heat treatment, due to the high strain-rate deformation. In the case of Zn coated steels to Al, and Mg-Al welds, the presence of low melting point reactions led to liquation at the welding interface, despite the 'solid state' nature of the welding processes. Solutions were explored to produce more rapid welds and control the level of interfacial reaction. The results have been disseminated in over 40 publications and attracted interest from additional automotive companies, including Nissan, Honda, GM and Chrysler. |
Exploitation Route | The findings have been passed on to industrial collaborators and have been developed fra further within a Programme grant - LATEST2 |
Sectors | Aerospace Defence and Marine Manufacturing including Industrial Biotechology Transport |
Description | The results from the work have been presented at workshops with JLR and attracted visits from interest from additional automotive companies, including Nissan, Honda, GM and Chrysler, who have visited Manchester to discuss dissimilar joining. The work has thus influenced their thinking on adopting new dissimilar technologies. |
Sector | Aerospace, Defence and Marine,Manufacturing, including Industrial Biotechology,Transport |
Impact Types | Economic |
Description | EPSRC Pogramme Grant |
Amount | £5,762,121 (GBP) |
Funding ID | EP/H020047/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 06/2010 |
End | 01/2016 |
Description | Friction Joining - Low Energy Manufacturing for Hybrid Structures in Fuel Efficient Transport Applications (JLR) |
Organisation | Jaguar Land Rover Automotive PLC |
Department | Jaguar Land Rover |
Country | United Kingdom |
Sector | Private |
PI Contribution | Research into dissimilar, friciton and ultrasonic welding |
Collaborator Contribution | Funded an EngD student on USW and sponsored a PhD student In-kind support in developing a USW manufacturing cell |
Impact | The work has influenced their thinking on adopting new welding technologies for light alloys. |
Start Year | 2009 |
Description | Friction Joining - Low Energy Manufacturing for Hybrid Structures in Fuel Efficient Transport Applications (Novelis) |
Organisation | Novelis Global Research and Technology Center |
Country | United States |
Sector | Private |
PI Contribution | Supply of materials and interest in outcomes for automotive manufacturing |
Collaborator Contribution | Supply of al-alloys to project and technical advice |
Impact | The work has thus influenced their thinking on joining aluminium intensive multi-material strucutres in automotive |
Start Year | 2009 |