A New Concept for Producing High Strength Aluminum Line-Joints in Car Body Assembly by a Robot Guided Friction Stir Welding Gun

Walz, Dominik; Werz, Martin; Weihe, Stefan

doi:10.1007/978-3-662-62962-8_42

Cited by 3 publications

(3 citation statements)

References 10 publications

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“…In addition, both friction stir welding and friction stir spot welding are scalable to automated solutions with robots resulting in a significant increase in production. 37 Sheet metal body and engine support frames can be friction welded: bumper beams, air suspension systems, intake manifolds and much more. 38 The undoubted advantages of this technology have always made it particularly attractive to major vehicle manufacturers, for example, Mazda first employed it in 2003 in the rear door panels of the Mazda RX-8 and later in 2005 for the Mazda MX-5 sports car.…”

Section: Non-fusion Welding Processesmentioning

confidence: 99%

Innovative joining technologies for lightweight material vehicles

Papa,

Panico,

Carandente

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part C:

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The transport industry is one of the most important for society and its economic growth. In Europe, this is especially true for road transport, which is an essential pillar for employment, trade, and economic development. The challenge is to minimize energy and cost and maximize efficiency while ensuring comfort and safety. This is the driving force behind technological progress that with social changes (such as, changing consumer preferences, greater environmental awareness) and political changes is revolutionizing the way people and goods move. Nevertheless, the selection of lightweight materials is negligible; it could involve new manufacturing technologies and joining techniques. Jaguar Land Rover (JLR) has been one of the prominent car producers employing aluminum alloys since 2003. A typical JLR monocoque is characterized by 90% aluminum stampings components made of 5xxx and 6xxx series aluminum alloys. Audi Space Frame (ASF) represents an alternative interpretation of improved lightweight frame architecture, and it is characterized by aluminum for more than 80% with the residual parts in CFRP used for rear panels, tunnel and the components useful to higher torsional stiffness. A 30% weight decrease is reached with respect to traditional steel corresponding elements. This review shows an overview of the challenges and opportunities for automotive body structures in the coming years while maintaining the goal of reducing mass and improving sustainability without increasing costs and impacting safety. This manuscript first evaluates how we can reduce mass in vehicles minimizing the carbon footprint and developing recyclable structures. The potential of new materials will be shown in light of the design constraints and the choice of technology used. The final remarks will discuss opportunities for engineering innovation dictated by this period of great changes and needs.

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Section: Non-fusion Welding Processesmentioning

confidence: 99%

Innovative joining technologies for lightweight material vehicles

Papa,

Panico,

Carandente

et al. 2024

Proceedings of the Institution of Mechanical Engineers, Part C:

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show abstract

“…In the shipbuilding and automotive industries, robotic welding vision sensors play a crucial role in ensuring the quality and accuracy of welding processes [ 126 , 127 , 128 , 129 , 130 , 131 , 132 , 133 ]. These sensors are designed to detect various parameters such as the thickness and shape of steel plates, the position and orientation of car parts, and the consistency of welds.…”

Section: Robotic Welding Sensors In Industrial Applicationsmentioning

confidence: 99%

Visual Sensing and Depth Perception for Welding Robots and Their Industrial Applications

Wang,

Li,

2023

Sensors

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With the rapid development of vision sensing, artificial intelligence, and robotics technology, one of the challenges we face is installing more advanced vision sensors on welding robots to achieve intelligent welding manufacturing and obtain high-quality welding components. Depth perception is one of the bottlenecks in the development of welding sensors. This review provides an assessment of active and passive sensing methods for depth perception and classifies and elaborates on the depth perception mechanisms based on monocular vision, binocular vision, and multi-view vision. It explores the principles and means of using deep learning for depth perception in robotic welding processes. Further, the application of welding robot visual perception in different industrial scenarios is summarized. Finally, the problems and countermeasures of welding robot visual perception technology are analyzed, and developments for the future are proposed. This review has analyzed a total of 2662 articles and cited 152 as references. The potential future research topics are suggested to include deep learning for object detection and recognition, transfer deep learning for welding robot adaptation, developing multi-modal sensor fusion, integrating models and hardware, and performing a comprehensive requirement analysis and system evaluation in collaboration with welding experts to design a multi-modal sensor fusion architecture.

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“…In this study, the weld characteristics and mechanical properties of intersecting stitch FSW welds in butt configuration were investigated. With a self-developed friction stir welding gun using a linear kinematic reported in [ 25 ], such welds can be produced on a flexible robot system. Figure 2 shows a comparison of the kinematics used in this study in contrast to the literature.…”

Section: Introductionmentioning

confidence: 99%

Effect of Weld Length on Strength, Fatigue Behaviour and Microstructure of Intersecting Stitch-Friction Stir Welded AA 6016-T4 Sheets

et al. 2023

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Friction stir welding is a promising joining process for boosting lightweight construction in the industrial and automotive sector by enabling the weldability of high-strength aluminum alloys. However, the high process forces usually result in large and heavy equipment for this joining method, which conflicts with flexible application. In order to circumvent this issue, a friction stir welding gun has been developed which is capable of producing short stitch welds—either stand-alone as an alternative to spot welds or merging into each other appearing like a conventional friction stir weld. In this study, the influence of the stitch seam length on the strength properties of intersecting friction stir welds is investigated, and the weld is characterized. For this purpose, EN AW-6016 T4 sheets were welded in butt joint configuration with varying stitch lengths between 2 and 15 mm. Both the static and dynamic strength properties were investigated, and hardness and temperature measurements were carried out. The results show a scalability of the tensile strength as well as the fatigue strength over the stitch seam length, while the substitute proof strength is not affected. Hereby, the tensile strength reached up 80% of the base materials tensile strength with the chosen parameter setup. Likewise, the stitch weld length influences the hardness characteristics of the welds in the transition area.

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A New Concept for Producing High Strength Aluminum Line-Joints in Car Body Assembly by a Robot Guided Friction Stir Welding Gun

Cited by 3 publications

References 10 publications

Innovative joining technologies for lightweight material vehicles

Innovative joining technologies for lightweight material vehicles

Visual Sensing and Depth Perception for Welding Robots and Their Industrial Applications

Effect of Weld Length on Strength, Fatigue Behaviour and Microstructure of Intersecting Stitch-Friction Stir Welded AA 6016-T4 Sheets

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