FSW Process Development (WP1)
Demonstrated production of:
• 60 m of high-quality welds in 6 mm S355 steel
• 30 m of high-quality welds in 12 mm S355 steel
in air and underwater.
Validated robustness of 6 mm and 12 mm tools under underwater thermal shock.
Achieved high-quality lap and butt welds in air and underwater.
Improved understanding of the relationship between welding parameters, microstructures and weld properties, enabling improved optimisation.
Documented route to industrial adoption (incl. ship classification requirements, D1.9).
Supported establishment of an ISO working group for steel FSW.
WP1 objectives fully achieved; FSW validated as an industrially viable process for up to 12 mm steel.
Early progress enabled:
Expanded parameter development (additional grades/thicknesses).
Deeper investigation of defect mechanisms and mitigation.
Earlier data provision to WP3/WP4, enabling faster development of underwater and retrofit systems.
Digital Platform and AI/ML for FSW Monitoring (WP2)
Developed AI/ML algorithms using Acoustic Emission (AE) data for defect identification.
Implemented a combined unsupervised + supervised ML approach, providing reliable anomaly detection.
Delivered a digital platform (alpha → beta) integrating:
• CAD and Digital Twin simulation
• Real-time data visualisation
• Secure industrial communication (Industry 4.0)
• Remote connectivity and control of the FSW robot via TeamViewer API
Built a database for real-time and historical process data.
Completed training activities; content remains available on the project website.
Underwater Robotic FSW System (WP3)
Completed full optioneering for the underwater FSW tool and clamping system (functional analysis, concept generation, PUGH matrix).
Delivered D3.1 (clamping technology selection).
Validated hull cleaning, surveying and 3D reconstruction using University of Limerick’s ROV systems (D3.2).
Delivered underwater repair protocol (D3.3) completed by FORTH after NED’s withdrawal.
Modular Build and Retrofit FSW Head (WP4)
Mapped shipyard capabilities and CNC resources and identified requirements for modular FSW.
Designed, manufactured and successfully tested the prototype FSW head for modular steel outfitting in a shipyard (Istanbul).
Demonstration Activities (WP5)
All three main RESURGAM solutions were successfully demonstrated (D5.1–D5.3):
Digital platform
Modular build solution
Underwater repair solution
Main Results Achieved
Industrial validation of FSW for steel in air and underwater (up to 12 mm).
Advancement of metallurgical understanding of steel FSW and associated defects.
Delivery of a functional digital platform integrating design, simulation, monitoring and control.
Development and validation of the underwater robotic repair concept.
Successful integration of FSW into modular shipbuilding processes.
Exploitation and Dissemination (Final Period)
Developed an initial business plan, stakeholder list and market engagement strategy.
Active collaboration with two other maritime RDI projects to support joint exploitation and synergies.
Post-project dissemination at TRA 2024.
Established project brand, website, social media, and dissemination materials.
Participated in key events:
• 3 × IIW Annual Conferences
• International Congress on Ship and Marine Technology
• Arsenal do Alfeite event
• Navalia exhibition
• RESURGAM seminars in Lisbon, Sheffield, Istanbul, Limassol, and Maryport
Produced:
• Podcast and multiple FSW demonstration videos (>4k views)
• Technical articles and 2 technical booklets
• 6 newsletters, press releases, news items
• Joint activities with sister projects
Project Management: Successfully managed withdrawal of NED-Project and integration of ASTANDER. All deliverables submitted on time; all activities completed as planned. Financial execution remained stable despite rising material/energy costs and supply-chain challenges.
