Highspeed-FSW - Digital Methods for an Improved Process Understanding for the Economic Application of Friction Stir Welding for Series Manufacturing

• Applicant: Professor Dr.-Ing. Peter Eberhard
• Subject Area: Production Automation and Assembly Technology
• Term: since 2024
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 539323882

The project deals with the preparation of friction stir welding (FSW) for potential series production processes. The aim is to achieve sufficient economic efficiency and process stability through a significant increase in process speed and reliable prediction of tool life. The approach consists of linking improved process simulations with systematic modification of tool geometry and process parameters as well as integrated sensory process monitoring for the FSW of high-strength aluminium alloys. The focus is on the further development of the Smoothed Particles Hydrodynamics (SPH) method for process simulation, experimental validation and the development of sensor-based process monitoring using an Explainable AI model (XAI). The results will be processed together with the industrial partners Airbus Operations GmbH and Hufschmied Zerspanungssysteme GmbH with a view to series production of aircraft outer skin structures.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: Airbus Operations GmbH; Hufschmied Zerspanungssysteme GmbH
• Cooperation Partner: Dr.-Ing. Axel Jahn