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Development and application of hybrid joining in lightweight integral aircraft structures

DAHLIAS

Development and application of hybrid joining in lightweight integral aircraft structures

Call for proposal: 
H2020-CS2-CFP07-2017-02
Link to CORDIS:
Objectives: 

The main objective of the DAHLIAS project is to optimise hybrid joining (Refill Friction Stir Spot Welding, RFSSW, with an adhesive sealant bond) for application in aircraft structures. RFSSW is a solid-state joining technology especially applicable to lightweight alloys in similar and dissimilar configurations. The process has been successfully applied to difficult-to-weld and non-weldable alloys and is considered a potential replacement of mechanical fastening.

Overlap joints in aircraft structures require the use of sealants for corrosion protection reasons. Using sealants with an adhesive function would complement the high-quality joints produced by RFSSW by not only protecting against corrosion but also contributing to the overall mechanical performance of the structure.

Methodology: 

To achieve the main goal of this project a work plan consisting of eight work packages has been devised.

Two work packages are focused on the RFSSW process development using standard samples with and without adhesive sealant. In parallel the adhesive sealant technology, including surface pre-treatment will be developed.

The hybrid joining solution developed in this project will be compared to conventional joining technologies to define its potential. Hybrid joining brings several advantages to production and performance of aircraft structures. The change from differential to integral design introduces new challenges in the analysis of mechanical performance. Hence, the damage tolerance behaviour of hybrid joints is also investigated in this project. Quality control methods will be investigated by selecting NDT methods and by process control based on online monitoring of parameters.

In the last phase of this project technology demonstrators will be produced to evaluate the capabilities of the proposed technology in actual aircraft structures. The consortium (3 R&D and 2 industrial partners) has the exact fitting, proven expertise and high excellence. HZG (coordinator) holds key patents.

Institution Type:
Institution Name: 
European Commission
Type of funding:
Programme Other: 
JTI-CS2-2017-CfP07-AIR-02-58 Optimization of hybrid joining (Refill Friction Stir Spot Welding + adhesive bond) for increasing mechanical properties and corrosion protection of the joints [SAT]
Lead Organisation: 

Helmholtz-Zentrum Geesthacht Zentrum Fur Material- Und Kustenforschung Gmbh

Address: 
MAX PLANCK STRASSE 1
21502 GEESTHACHT
Germany
EU Contribution: 
€283,225
Partner Organisations: 

Chemetall Gmbh

Address: 
Trakehner Strasse 3
60487 Frankfurt Am-Main
Germany
EU Contribution: 
€66,063

Tra-C Industrie Sas

Address: 
ZAC LES OLMES
69490 LES OLMES
France
EU Contribution: 
€120,838

Institut De Soudure

Address: 
Rue des Vanesses 90 - Zone Industrielle Paris-Nord II
93420 VILLEPINTE
France
EU Contribution: 
€263,250

Belgisch Instituut Voor Lastechniek Vzw

Address: 
ANTOON VAN OSSLAAN 1-4
1120 BRUSSEL
Belgium
EU Contribution: 
€220,513
Technologies: 
Development phase: