Friction Element Welding Innovations for hybrid body parts Dr. Uwe Alber (AUDI AG) April, 19 th 2012
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1 Friction Element Welding Innovations for hybrid body parts Dr. Uwe Alber (AUDI AG) April, 19 th 212 1
2 Contents Motivation Properties of the joints Manufacturing equipment Process operation Mechanical strength and hardness Quality assurance: destructive and non-destructive testing Equipment test in the serial production line Summary and perspective 2 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
3 Motivation increasing use of press hardened steel parts in steel-, ASF - and hybrid bodies AUDI A4: steel body in white dominant joining technologies: spot welding laser welding, laser brazing structural adhesives AUDI A8: audi space frame (ASF ) dominant joining technologies: self piercing riveting flow drill screwing MIG welding laser welding 3 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
4 Contents Motivation Properties of the joints Manufacturing equipment Process operation Mechanical strength and hardness Quality assurance: destructive and non-destructive testing Equipment test in the serial production line Summary and perspective 4 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
5 Properties of the joints Plus Minus One of the few methods to join aluminium onto press hardened steels (22MnB5) Two side accessibility Need of an extra element Head side elevation (3 mm) Joining direction from aluminium to steel Head side PVC-sealing in wet zone needed No pre hole operation needed High mechanical strength of the joint allows reduction of the number of joints Combinability with adhesives 5 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
6 Contents Motivation Properties of the joints Manufacturing equipment Process operation Mechanical strength and hardness Quality assurance: destructive and non-destructive testing Equipment test in the serial production line Summary and perspective 6 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
7 Manufacturing equipment friction element welding head process control unit linear motor rotation motor flexible feeding tube linear unit element feeding unit element separator hold down ambos 7 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
8 Contents Motivation Properties of the joints Manufacturing equipment Process operation Mechanical strength and hardness Quality assurance: destructive and non-destructive testing Equipment test in the serial production line Summary and perspective 8 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
9 Process flow - overview Welding process Element feeding Open/close clamp Welding process Element feeding Robot movement Robot movement time[s] 9 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
10 Principal process flow Rotating element heats alumimium part Aluminium Steel (22MnB5) Rotating element penetrates alumimium part under axial pressure Aluminium Steel (22MnB5) Friction of rotating element leads to heat the underneath steel part Aluminium Steel (22MnB5) Welding of the element to underneath steel part and binding of the penetrated aluminium part Aluminium Steel (22MnB5) 1 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
11 Process flow 11 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
12 Process flow high speed film 12 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
13 Energie x1 [Ws] Weg [mm] Drehmoment [Nm] Axialkraft [kn] Drehzahl x1 [1/min] Process flow - details Rotational speed Axial force Torque Distance ,5 1 1,5 2 2,5 Zeit [s] ,5 1 1,5 2 2,5 Zeit [s] ,5 1 1,5 2 2,5 4 3,5 3 2,5 2 1,5 1,5 Zeit [s],5 1 1,5 2 2,5 Zeit [s] 2,5 Energy 2 1, Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212,5,5 1 1,5 2 2,5 Zeit [s] time
14 Contents Motivation Properties of the joints Manufacturing equipment Process operation Mechanical strength and hardness Quality assurance: destructive and non-destructive testing Equipment test in the serial production line Summary and perspective 14 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
15 Force Kraft [N] Strain Arbeit energy bis Fmax [Nmm] Force Kraft [N] Strain Arbeit bis energy Fmax [Nmm] Mechanical strength - variation of Al-sheet thickness Tensile shear stress (parallel to surface) Deckblech s. Tabelle Fügeparameter Basismaterial 22MnB5 1,2mm Prüfumfang n=7 Fügeparameter Tensile strength and strain energy correlates to sheet thickness Fracture always in the Al-sheet s. Tabelle Fügeparameter Prüfmethode quasistatischer Scherzugversuch No fracture in the welding zone Prüfmaschine Zwick Z 2 Probenform TL91 1,mm TL91 1,2mm TL91 1,5mm TL91 2,mm Tensile shear stress (perpendicular to surface) Performance similar to tensile shear stress (parallel to surface) Thin Al sheet fracture in Al Thick Al sheet fracture in steel No fracture in the welding zone Deckblech s. Tabelle Fügeparameter Basismaterial 22MnB5 1,2mm Prüfumfang n=7 Fügeparameter s. Tabelle Fügeparameter Prüfmethode quasistatischer Schälzugversuch Prüfmaschine Zwick Z 2 Probenform TL91 1,mm TL91 1,2mm TL91 1,5mm TL91 2,mm 15 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
16 Kraft Force [N] [N] Reibenergie [J] Kraft Force [N] [N] Reibenergie [J] Mechanical strength - variation of steel-sheet thickness Tensile shear stress (parallel to surface) MnB5 1,mm RE 3,5mm 22MnB5 1,2mm RE 3,5 22MnB5 1,7mm RE 4mm 22MnB5 2,mm RE 4,5mm Deckblech TL91 1,2mm Basismaterial s. Tabelle Fügeparameter Prüfumfang n=7 Fügeparameter s. Tabelle Fügeparameter Prüfmethode quasistatischer Scherzugversuch Prüfmaschine Zwick Z 2 Probenform Tensile strength independent of steel-sheet thickness Failure mode: fracture in Al-sheet Friction energy increases with increasing steel-sheet thickness Tensile shear stress (perpendicular to surface) Performance similar to tensile shear stress (parallel to surface) Deckblech TL91 1,2mm Basismaterial s.tabelle Fügeparameter Prüfumfang n=7 Fügeparameter Thin steel sheet fracture in steel MnB5 1,mm RE 3,5mm 22MnB5 1,2mm RE 3,5mm 22MnB5 1,7mm RE 4mm 22MnB5 2,mm RE 4,5mm s. Tabelle Fügeparameter Prüfmethode quasistatischer Schälzugversuch Prüfmaschine Zwick Z 2 Probenform 16 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
![Kraft Force [N] [N] Arbeit bis Fmax [Nmm] Strain energy [Nmm] Kraft Force [N] [N] Arbeit Strain bis energy Fmax [Nmm] [Nmm] Mechanical strength combination with adhesives Tensile shear stress](/docs-images/74/70595739/images/17-0.jpg "(parallel to surface) 12 11 1 9 8 7 6 5 4 3 2 1 Klebstoff ausgehärtet Klebstoff unausgehärtet ohne Klebstoff 2 18 16 14 12 1 8 6 4 2 Deckblech TL91 1,2mm Basismaterial 22MnB5 1,2mm Prüfumfang n=7")
17 Kraft Force [N] [N] Arbeit bis Fmax [Nmm] Strain energy [Nmm] Kraft Force [N] [N] Arbeit Strain bis energy Fmax [Nmm] [Nmm] Mechanical strength combination with adhesives Tensile shear stress (parallel to surface) Klebstoff ausgehärtet Klebstoff unausgehärtet ohne Klebstoff Deckblech TL91 1,2mm Basismaterial 22MnB5 1,2mm Prüfumfang n=7 Fügeparameter s. Tabelle Fügeparameter Prüfmethode quasistatischer Scherzugversuch Prüfmaschine Zwick Z 2 Probenform Cured adhesive strongly increases tensile strength Uncured adhesive doesn t affect tensile strenght Failure mode: fracture in Al-sheet Tensile shear stress (perpendicular to surface) Cured adhesive doesn t strongly increase tensile strength Uncured adhesive doesn t affect tensile strenght Failure mode: fracture in Al-sheet Klebstoff ausgehärtet Klebstoff unausgehärtet ohne Klebstoff Deckblech TL91 1,2mm Basismaterial 22MnB5 1,2mm Prüfumfang n=7 Fügeparameter s. Tabelle Fügeparameter Prüfmethode quasistatischer Schälzugversuch Prüfmaschine Zwick Z 2 Probenform 17 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
![2 3 4 5 6 7 8 9 1 11 Position [mm] Steel: (1,5 mm) Usibor DP6](/docs-images/74/70595739/images/18-1.jpg "Testing method Vickers Hardness (HV,5) Friction element Aluminium")
18 HV,5 DP6 Var. 1 HV,5 Usibor Var. 1 Microhardness testing comparison of different steels Position [mm] Steel: (1,5 mm) Usibor DP6 Testing method Vickers Hardness (HV,5) Friction element Aluminium Steel Dualphase steel (DP6) Hardening in the heat affected zone Position [mm] Presshardened steel (USIBOR ) Decreasing hardness around the heat affected zone Normalization of the microstructure 18 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
19 Upper Oberlast load F o F [N] [N] Fatigue behaviour Scherzug Reibelementschweißen Schälzug Reibelementschweißen Scherzugproben Vollstanzniet 4 mm k = 4,136 log A = 23,4 Tn = 1 : 2,5 k = 1,53 log A = 47,589 Tn = 1 : 7,1 Blechwerkstoffe: TL 91, t = 1,15 mm 22 MnB5 t = 1,5 mm Fügeparameter Reibelementlänge l: 3,5 mm Setzlänge l s : 2,9 mm Drehzahl n: 55min -1 Anpresskraft F a : 6kN Versuchsführung: Lastgesteuert R = Fu / Fo =,1 Abschaltkriterien: 4% Änderung d. Schwingweges N = 5 x 1 6 Schwingspiele Durchläufer Probengeometrie: k = 2,882 log A = 15,334 Tn = 1 : 2, Schwingspielzahl Number of cycles N Scherzugprobe Schälzugprobe 19 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
20 force direction Failure modes Quasistatic shear stress Mode 1: fracture in Aluminium sheet Fatigue behaviour (Wöhler lines) Top view steel 1,5 mm Al 1,5 mm force direction Mode 2: fracture in steel sheet Cross sectional view steel 1, mm Al 1,5 mm Friction element (steel) Al steel 2 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
21 Force [N] Mechanical strength comparison of joining techniques Maximum tensile shear stress Reibelementschweißen 1,15mm TL91 auf 1,2mm USIBOR 6 Hochgeschwindigkeitsfügen 1,15mm TL91 auf 1,2mm USIBOR 5 Vollstanznieten (5mm Niet) 1,5 mm 22MnB5 auf 1,1 TL91 4 Widerstandselementschweißen 1,15 TL91 auf 1,5 mm 22MnB Friction element welding RIVTAC Self piercing riveting Resistance element welding 21 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
22 Contents Motivation Properties of the joints Manufacturing equipment Process operation Mechanical strength and hardness Quality assurance: destructive and non-destructive testing Equipment test in the serial production line Summary and perspective 22 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
23 Quality assurance destructive testing Visible inspection Cross sectional view (1) Cross sectional view (2) Minimum Aluminium bulge 2, mm around the friction element head 1, mm No cracks, pores, inclusions Significant heat affected zone in base material (steel) 1, mm Tight fitting between aluminium and friction element head 23 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
24 Quality assurance non-destructive testing Ultrasonic testing (US) Accordance between cross sectional and ultrasonic testing Strong detectability of cracks and failures parallel to surface Result: very small variation of total thickness (+/-,5 mm) 24 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
25 Contents Motivation Properties of the joints Manufacturing equipment Process operation Mechanical strength and hardness Quality assurance: destructive and non-destructive testing Equipment test in the serial production line Summary and perspective 25 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
26 Equipment test in serial production line AUDI A6 serial production 135. built joints 491 tested joints: Non-destructive test (US): 488 good / 3 bad joints Visible inspection (tight head fitting / positioning): 1% good Destructive test: a) Flat chisel test: 245 good joints (1%) b) cross sectional micrograph: 243 good / 3 bad (1,3%) joints 26 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
27 Contents Motivation Properties of the joints Manufacturing equipment Process operation Mechanical strength and hardness Quality assurance: destructive and non-destructive testing Equipment test in the serial production line Summary and perspective 27 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
28 Summary and perspective One of the few methods to join aluminium onto press hardened steels (22MnB5). This enables us to realize future concepts for hybrid car bodies High mechanical strength compared to other joinig techniques allows a reduction of the number of joints Successful qualification of non-destructive (ultrasonic) testing Continous development and optimization of the manufacturing equipment via use in AUDIs serial production lines Perspective: Reduction of head side elevation via new element geometry standard geometry new geometry 28 Dr. Uwe Alber, Friction Element Welding Innovations for hybrid body parts, April 212
29 Thank you for your attention! Dr. Uwe Alber (AUDI AG) 29
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