Joining and Assessment

Projects

Title: Material and cost saving production processes for titanium and new design of the joining area CFRP-Ti as hybrid structure for improvement of load transfer and life time

The project is funded within the Aviation Cluster Hamburg Metropolitan Region.
Topic of OPTISTRUCT ist the application of cost and resource saving production processes for titanium as well as new joining technologies between CFRP and titanium. Goal of the project is the identification of the optimization potential by establishing alternative process route for the production of integral Ti structures as well as the intelligent design of the interface Ti-CFRP with respect to cost effectiveness and performance improvement. The transferability to industrial application will be validated through the production of demonstrator samples.

Participants: FormTech GmbH (Coordinator), GKSS, Hein & Oetting Feinwerktechnik GmbH

Contact


Group Leader Joining and Assessment

Dr. Nikolai Kashaev

Institute of Materials Research

Max-Planck-Straße 1
21502 Geesthacht

Phone: +49 (0) 4152 87 2536,

E-mail contact

Title: Improvement in steel utilisation and manufacturing by recent break-through in high-power fibre laser welding

Aim of the FIBLAS project is to establish a European team to conduct innovative research to generate knowledge and technology to increase industrial efficiency while improving environmental aspects in major load bearing welded steel structures, exploiting the specific advantages of the high-power fibre laser. Specifically, shipbuilding, pipe production and pipelaying, both on- and offshore, are addressed. Corresponding to these subjects, the project covers a wide range of high strength steel sheets and pipes with regard to material composition and thickness. Furthermore, different joint geometries are needed. The investigations will lead to comprehensive knowledge on the potential use of high-power fibre laser welding (autogenous, with cold wire and hybrid) of advanced high-strength steels with their structural performance. The results are expected to enable the integration of high-power fibre laser welding processes into new fields of industry, which have not been accessible to laser welding technology previously (e.g. onshore girth welding in pipelaying).

Participants: BIAS Bremer Institut für angewandte Strahltechnik GmbH (DE), Schweisstechnische Lehr- und Versuchsanstalt SLV Mecklenburg-Vorpommern GmbH (DE), Cranfied University (UK), GKSS-Research Centre Geesthacht GmbH (DE), OCAS-Onderzoekscentrum voor Aanwending van Staal N. V. (BE), Salzgitter Mannesmann Forschung GmbH (DE), Corinth Pipeworks S. A. (GR), VIETZ GmbH (DE), SERIMER DASA S. A. S. (FR), Ingenieurtechnik und Maschinenbau GmbH (DE), AIR LIQUIDE/CTAS (FR), Vyskumny Ustav Zvaracsky - Priemyselny Institut SR Associacia (SK)

Contact


Head of Department Joining and Assessment

Dr. Nikolai Kashaev

Institute of Materials Research

Max-Planck-Straße 1
21502 Geesthacht

Phone: +49(0)4152 87-2536

E-mail contact

Title: Development of short distance welding concepts for airframes

The WEL-AIR framework constitutes a research and technological development project designed to generate new fundamental knowledge to develop new manufacturing approaches by using short distance joining technology for primary structural components (such as skin-frame, skin-cleat, cleat-striner etc.) of the metallic aircraft fuselage. For this purpose, optimum process-property and performance relationships need to be established by satisfying the fatigue and damage tolerance requirements. The research methodology used in this project will follow "develop - test - verify - make recommendations" steps to establish new short distance welding concepts for cost-effective manufacturing of the airframes using Laser Beam Welding and Friction Steer Welding processes. The "testing - verification" steps will be covered by conducting extensive damage tolerance analysis in terms of fatigue, fracture toughness, corrosion, as well as non-destructive testing using various joint configurations and alloy combinations.

Participants: GIE EADS CCR (FR), GKSS-Research Centre Geesthacht GmbH (DE), Airbus Deutschland GmbH (DE), Airbus France SAS (FR), EADS Deutschland GmbH (DE), Office National d'Etudes et de Recherches Aerospatials (FR), Pechiney Centre de Recherche de Voreppe (FR), Societe Anonyme Belge de Constructions Aeronautiques (BE), Dassault Aviation S.A. (FR), DLR (DE), Alenia Aeronautica SPA (IT), ISTRAM (GR), Piaggio Aero Industries S.P.A. (IT), Institut de Soudure (FR)

Contact


Head of Department Joining and Assessment

Dr. Nikolai Kashaev

Institute of Materials Research

Max-Planck-Straße 1
21502 Geesthacht

Phone: +49(0)4152 87-2536

E-mail contact

Title: European fitness for service network

FITNET Fitness-for-Service (FFS) procedure is developed by over 60 experts from 16 European countries within the European thematic network project FITNET (2002 – 2006) for the assessment of metallic structures with and without welds containing, or postulated to contain, flaws. The failure mechanisms considered are fracture, fatigue, creep and corrosion, together with combinations of these failure modes. During the development of the FITNET FFS Procedures, close contact and collaborations with experts from Japan, USA and Korea have been established. The experts from those countries have worked within the FITNET working groups and provided technical contributions for the development of various sections.

FITNET FFS assessment results can provide information on material selection and hence the most suitable component fabrication route for safe and economical performance.

FITNET FFS Procedure Revision MK8 is in detail given in Volume I which facilitates unified and updated structural integrity assessment routes through the main sections such as:

  • Information required for assessment;
  • Assessment Modules (Fracture, Fatigue, Creep, Corrosion);
  • Assessment and reporting of results;
  • Alternative and specific assessments for fracture;
  • Additional information for fracture assessment.

The Volume II contains Annexes which present solutions enabling the FITNET FFS Procedure to be applied. These Annexes provide primary sources of information on limit loads (incl. strength mismatch), stress intensity factor solutions for various geometries, weld residual stress distributions and beta solutions etc.

Accompanying validation and worked examples are available in volume of Case Studies and Tutorials (used in FITNET training and education seminars). Furthermore, the Proceedings of the FITNET 2006 International Conference provide information on the features of the procedure, exercises and recent developments in FFS technology world wide with 32 papers.

Contact


Head of Department Joining and Assessment

Dr. Nikolai Kashaev

Institute of Materials Research

Max-Planck-Straße 1
21502 Geesthacht

Phone: +49(0)4152 87-2536

E-mail contact