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BIA-Brukerstyrt innovasjonsarena

BOOST: Novel solid-state bonding technology involving addition of filler metals for flexible design and production of multimaterial products

Alternative title: BOOST: Ny metode for fastfasesveising som involverer tilsetning av sveisemetall for fleksibel design og produksjon av multimaterialprodukter

Awarded: NOK 2.6 mill.

Project Number:

313894

Project Period:

2020 - 2023

Funding received from:

Organisation:

Sustainable, light weight and high-performance products are of undeniable importance towards the low-carbon circular economy. New multi-material products (MMPs) are regarded as the global trend with respect to product design and optimal choice of materials while also taking the concept of Design-for-Disassembly and recyclability into account. However, a broader application of the promising multi-material solutions is still hindered by restricted design flexibility, challenging joining, high risk of interfacial cracking and lack of predictability of properties. The Boost will further develop the novel Hybrid Metal Extrusion & Bonding (HYB) technology, which is a solid-state joining process for metallic materials involving the addition of filler metals, enabling fabrication of defect-free, design-flexible, production-effective and high-performance MMPs. This project will focus on three innovation solutions: 1) the HYB PinPoint Extruder, which is the core of the HYB technology; 2) addition of the filler metal, which is a unique feature of the HYB process; and 3) the HYB process monitoring and quality control system. The HYB technology developed in the Boost project will enable sustainable and flexible manufacturing of multi-material products. Successful implementation of the innovations will enable smarter and more innovative use of "green" materials like aluminium in various applications covering different industry sectors. In 2021, all the milestones in the project have been reached: -New experimental filler metal has been develpoped and produced, two different alloys where both are supplied with two different homogenization procedures. The four candidate materials will further be extruded and drawn into welding wire, which will be used in welding experiments. -A new PinPoint Extruder has been designed, which is adapted to industrial scale implementation by the partners in the project. -The HYB "workbench" in Trondheim has been upgraded. In order to fully utilize all the possibilities with the HYB process, it is decided to work further with the development of the control system in 2022. -A new process model for steel-aluminum welding has been developed using the HYB technology. This model is now fully developed. Hydro's NaMo model is used to calculate the microstructure development in HAZ on the aluminum side of the weld.

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The Boost project aims to further develop the novel Hybrid Metal Extrusion & Bonding (HYB) technology, which is a solid-state joining process for metallic materials involving the addition of filler metals (FMs), enabling fabrication of defect-free, design-flexible, production-effective and high-performance multi-material products (MMPs). This will be made possible through development of the planned innovation in the project, which will lay a foundation for industrialization of the HYB technology. The R&D challenges that will be addressed in the Boost project include: 1) re-design the HYB PinPoint Extruder and optimize the shape of rotating pin, extrusion chamber and stationary housing to increase the aptness of the HYB process for manufacturing of MMPs; 2) understand the strengthening mechanisms in aluminium alloys and use this knowledge to tailor the properties of the new filler metals for HYB joining of dissimilar metals and alloys; 3) control and optimize the manufacturing route for the new filler metals and 4) increase the stability and robustness of the HYB process by developing a new process monitoring and quality control system. Through the fulfillment of the goals of the Boost project, the industrial partners will be ready to deliver new products and services to the targeted markets, with HyBond as the new joining solution supplier, Hydro as the aluminium alloy and new filler metal manufacturer and supplier and Marine Aluminium as the pilot industrial MMPs manufacturer.

Funding scheme:

BIA-Brukerstyrt innovasjonsarena