Frank Vollertsen

Gap tolerant joining of aluminum with steel sheets using the hybrid technique

Laser joining of dissimilar materials is one of the core competences of BIAS and is from interest focusing new design concepts for weight savings in different fields in automotive and aeronautic industry. Beside the development of joining techniques for thin aluminum-steel sheets, the joining of thicker material is of interest. Therefore specific processes have to be developed which allow dissimilar joints with small intermetallic phases. By using a hybrid process (Nd:YAG-Laser+MIG), a gap tolerant joining of aluminum-steel joints with a thickness of 3–4 mm, in butt-joint configuration is possible. Furthermore, the developed process allows a flux free joining of these dissimilar material combinations. For the characterization of the joining zone microstructural examinations have been carried out by optical and electron microscopy as well as electron backscattered diffraction analyses. Additionally, results from mechanical examinations like tensile and fatigue tests will be reported.Laser joining of dissimilar materials is one of the core competences of BIAS and is from interest focusing new design concepts for weight savings in different fields in automotive and aeronautic industry. Beside the development of joining techniques for thin aluminum-steel sheets, the joining of thicker material is of interest. Therefore specific processes have to be developed which allow dissimilar joints with small intermetallic phases. By using a hybrid process (Nd:YAG-Laser+MIG), a gap tolerant joining of aluminum-steel joints with a thickness of 3–4 mm, in butt-joint configuration is possible. Furthermore, the developed process allows a flux free joining of these dissimilar material combinations. For the characterization of the joining zone microstructural examinations have been carried out by optical and electron microscopy as well as electron backscattered diffraction analyses. Additionally, results from mechanical examinations like tensile and fatigue tests will be reported.

Development of a new joining technology for hybrid metal aircraft structures

With the introduction of the laser beam welding of skin-stringer-joints into the aircraft industry, Airbus set a new standard for the processing of metallic materials. New design principles and joining processes for high performance materials enhance the overall performance of the integral metallic fuselage. Improved exploitation of material properties is driving the development of ‘tailored’ hybrid components. The newly developed laser beam joining process of aluminium and titanium offers the chance to create low weight and corrosion resistant hybrid structures like seat tracks.With the introduction of the laser beam welding of skin-stringer-joints into the aircraft industry, Airbus set a new standard for the processing of metallic materials. New design principles and joining processes for high performance materials enhance the overall performance of the integral metallic fuselage. Improved exploitation of material properties is driving the development of ‘tailored’ hybrid components. The newly developed laser beam joining process of aluminium and titanium offers the chance to create low weight and corrosion resistant hybrid structures like seat tracks.