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Development and application of hybrid joining in lightweight integral aircraft structures

Objective

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. 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 a number of 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, prooven expertise and high excellence. HZG (coordinator) holds key patents.

Coordinator

HELMHOLTZ-ZENTRUM HEREON GMBH
Net EU contribution
€ 283 225,00
Address
Max Planck Strasse 1
21502 Geesthacht
Germany

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Region
Schleswig-Holstein Schleswig-Holstein Herzogtum Lauenburg
Activity type
Research Organisations
Non-EU contribution
€ 0,00

Participants (4)

INSTITUT DE SOUDURE ASSOCIATION
France
Net EU contribution
€ 263 250,00
Address
Rue Des Vanesses 90 Zi Paris Nord
93420 Villepinte

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Region
Ile-de-France Ile-de-France Seine-Saint-Denis
Activity type
Research Organisations
Non-EU contribution
€ 0,00
BELGISCH INSTITUUT VOOR LASTECHNIEK VZW
Belgium
Net EU contribution
€ 220 512,50
Address
Antoon Van Osslaan 1
1120 Brussel

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Region
Région de Bruxelles-Capitale/Brussels Hoofdstedelijk Gewest Région de Bruxelles-Capitale/ Brussels Hoofdstedelijk Gewest Arr. de Bruxelles-Capitale/Arr. Brussel-Hoofdstad
Activity type
Research Organisations
Non-EU contribution
€ 0,00
CHEMETALL GMBH
Germany
Net EU contribution
€ 66 062,50
Address
Trakehner Strasse 3
60487 Frankfurt Am Main

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Region
Darmstadt Frankfurt am Main, Kreisfreie Stadt
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Non-EU contribution
€ 28 312,50
TRA-C INDUSTRIE SAS
France
Net EU contribution
€ 120 837,50
Address
Zac Les Olmes
69490 Les Olmes

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SME

The organization defined itself as SME (small and medium-sized enterprise) at the time the Grant Agreement was signed.

Yes
Region
Auvergne-Rhône-Alpes Rhône-Alpes Rhône
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
Non-EU contribution
€ 51 787,50