Friction stir welding (FSW), as a solid-state joining technology, is ideally suited for producing high-strength joints in dissimilar materials such as aluminum and steel. This method is particularly advantageous for manufacturing hybrid Aluminum-Steel Tailor Welded Blanks (TWB), which are essential for achieving lightweight construction in the automotive industry. However, despite its benefits, the FSW process can exhibit variability in joint strength and formability, particularly in the complex configurations required for deep drawing applications.
The CO2-HyChain project, part of the federally funded “Technologietransfer-Programm Leichtbau” (TTP LB), addresses these challenges by optimizing the FSW process, along with subsequent heat treatment and deep drawing techniques for hybrid TWBs. A key focus of the project is to enhance the formability of the blanks while ensuring the robustness and consistency of the welding process.
This presentation will discuss the significant achievements in improving both the welding process and the associated formability of hybrid TWBs. The research findings underscore that the selection of tool material plays a pivotal role in enhancing weld integrity and maintaining consistent weld quality across various production scales. Furthermore, innovations in material and process technologies are highlighted as key drivers in advancing lightweight construction within the automotive sector.
The collaboration between research institutions and industry partners within the CO2-HyChain project demonstrates a successful model for translating laboratory-scale research into practical industrial applications, ultimately contributing to substantial reductions in CO2 emissions through improved vehicle design and production techniques.