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Automated scanner for kissing bond detection in friction stir welded materials

Objective

Friction Stir Welding (FSW) is a material joining technique that is a major breakthrough due to its substantial advantages compared to other techniques for welding aluminum alloys. This has allowed aircraft manufacturers such as Boeing to achieve 60% cost saving and reduce manufacturing time by 73% in aircraft models. This is only a fraction of what could be achieved. Despite its merits, FSW use is still limited due to a certain defect termed “kissing bond”. Kissing bonds reduce the stress-load resilience of FSW materials and are extremely difficult to detect. Thus, out of fear of low fatigue performance, aerospace and automotive manufacturers cannot leverage FSW to its full potential which translates to manufacturing cost savings of €1.6 billion, fuel savings of €1.9 billion and a reduction of 2 million tons of CO2, during the next 20 years.

This gap gives rise to a unique business opportunity which Vermon (developer of nonlinear ultrasonic transducers) and RISE (expert in signal processing algorithms), IKH (high-tech SME specializing in human-machine interfaces and service robotics) along with Coskunoz (leader in FSW machinery with commercial presence in 4 continents) seek to seize with the aid of TWI (world class research institute who originally invented FSW) by commercializing FrictionHarmonics.

FrictionHarmonics is the fruit of four years of R&D financed by private funds and public grants. It has already been validated in a relevant environment and is proved to detect kissing bonds of less than 0.3mm in diameter with 100% accuracy.

We now need to finalize the system’s commercial version, certify it, and validate its performance in a complete FSW production line. Our primary target customers will be aerospace and automotive manufacturers in Europe and North America. To this end, we request a grant of €2.2m. Our aim is to grow our businesses by €33.44m in gross cumulative revenue, operating at a profit of €13.83m and generating 215 new jobs over the 5 years after market launch.

Field of science

  • /social sciences/economics and business
  • /engineering and technology/electrical engineering, electronic engineering, information engineering/electronic engineering/signal processing
  • /engineering and technology/mechanical engineering/vehicle engineering/aerospace engineering/aircraft

Call for proposal

H2020-EIC-FTI-2018-2020
See other projects for this call

Funding Scheme

IA - Innovation action

Coordinator

VERMON SA
Address
Rue General Renault 180
37000 Tours
France
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
EU contribution
€ 458 978,63

Participants (4)

AINOOUCHAOU PLIROFORIKI AE
Greece
EU contribution
€ 439 793,39
Address
L Kiphisias 116 Kai Davaki 1
11526 Athina
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
TWI LIMITED
United Kingdom
EU contribution
€ 614 456,11
Address
Granta Park Great Abington
CB21 6AL Cambridge
Activity type
Research Organisations
COSKUNOZ KALIP MAKINA SANAYI VE TICARET ANONIM SIRKETI
Turkey
EU contribution
€ 269 514
Address
Bursa Organize Sanayi Bolgesi Sari Caddesi No 1
16140 Bursa
Activity type
Private for-profit entities (excluding Higher or Secondary Education Establishments)
RISE RESEARCH INSTITUTES OF SWEDEN AB
Sweden
EU contribution
€ 408 500
Address
Brinellgatan 4
501 15 Boras
Activity type
Research Organisations