Technologies for future aircraft

The research team that tested Friction Stir Welding for Saab's applications. Photo: University West

The welding technology tested by the researchers and Saab's development engineers is completely different from conventional welding technologies: Friction Stir Welding (FSW) has been around for nearly 30 years and is gaining increasing attention in various industrial applications.

Three metal layers joined in one weld

"Our interest in the technology was sparked in previous research work. For this project, we contacted University West, which is the only university in Sweden with the competence and equipment we need", says Stefan Borgenvall.

"The focus is on assembling aircraft structures in new, more efficient ways. Together, we have built a component from different aluminum alloys. This is part of a larger demonstrator. With this welding technology, we can, for example, join three metal layers in a single weld. We avoid drilling, using fasteners, and time-consuming post-sealing", says Stefan.

Seeing multiple advantages

The development of technology for aircraft manufacturing involves several challenges related to the high safety standards that the industry must always meet.

"We see several advantages with Friction Stir Welding and now want to move forward with investigating a number of questions. We need to ensure that the welding technology meets strength requirements. We need to create methods for continuous quality control in the production process. We are also looking into which components this technology could be applicable for", says Stefan.

"This type of process takes time, but in five years, I believe we could have components assembled using this welding technology in aircraft undergoing testing. It depends on what kinds of components we want to use the technology for", says Stefan.

"The interest in this welding technology is significant"

The research work is part of the extensive Vinnova-funded project IntDemo, where a number of different demonstrators have been developed to test various new technologies. In June, the results from all the subprojects were presented. The research team from University West was present.

"The interest in this welding technology is significant, but it is still not particularly well-known in all industries. The technology has several advantages: it produces strong welds without smoke, low energy consumption, and minimal waste. Additionally, production time is shorter", explains Vivek Patel, Associate Professor of Welding Technology at University West.

FACTS

• Friction Stir Welding is a welding process where frictional heat and mechanical pressure weld materials together without melting them. 
• The research group at University West in welding and welding-based additive manufacturing works interdisciplinary and is the largest in the Nordic region.
• University West offers Sweden's only master's program in welding technology and graduates IWE engineers.

Read more about the research project and Friction Stir Welding

Contact: Joel Andersson, Professor of Materials Science, University West