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A Friction Stir Welding case study using Temperature Controlled Robotics with a HPDC Cylinder Block and dissimilar materials joining
University West, Department of Engineering Science, Division of Welding Technology. (PTW)ORCID iD: 0000-0003-3261-9097
SKB AB, Oskarshamn, Sweden.
University West, Department of Engineering Science, Division of Production Systems. (PTW)ORCID iD: 0000-0001-9553-7131
Volvo Cars, Göteborg, Sweden.
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2019 (English)In: Journal of Manufacturing Processes, ISSN 1526-6125, Vol. 46, p. 177-184Article in journal (Refereed) Published
Abstract [en]

The automotive industry is going through a radical transformation from combustion engines to fully electric propulsion, aiming at improving key performance indicators related to efficiency, environmental sustainability and economic competitiveness. In this transition period, it is important to continue the innovation of combustion engines for e.g. plug-in hybrid vehicles. This led Volvo Cars to pursue radically new manufacturing processes such as Friction Stir Welding (FSW). The work presented in this paper is a case study whereby feasibility of using FSW to join a reinforcement element into the aluminium casted Cylinder Block was studied. The complex geometry of the joint required a flexible five-axis manipulator, i.e. an industrial robot, as well as advanced process control, i.e. temperature feedback control, in order to maintain a consistent weld quality throughout the whole component. The process was successfully demonstrated in a lab environment and offers a cost-efficient solution while maintaining the durability and higher efficiency. The outcome of this study shows the great potential of implementing the FSW process in combination with High Pressure Die Casted components, such a Cylinder Block. © 2019 The Society of Manufacturing Engineers

Place, publisher, year, edition, pages
Elsevier , 2019. Vol. 46, p. 177-184
Keywords [en]
Aluminum; Automotive industry; Benchmarking; Casting; Combustion; Competition; Cylinder blocks; Dissimilar materials; Efficiency; Friction; Friction stir welding; Industrial manipulators; Intelligent control; Manipulators; Plug-in hybrid vehicles; Research laboratories; Robots; Sustainable development; Temperature control, Advanced Process Control; Automotive; Economic competitiveness; Environmental sustainability; Friction stir welding(FSW); Key performance indicators; Manufacturing process; Radical transformation, Process control
National Category
Manufacturing, Surface and Joining Technology Robotics
Research subject
ENGINEERING, Manufacturing and materials engineering; Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-14487DOI: 10.1016/j.jmapro.2019.08.012ISI: 000493221100017Scopus ID: 2-s2.0-85072050179OAI: oai:DiVA.org:hv-14487DiVA, id: diva2:1356418
Available from: 2019-10-01 Created: 2019-10-01 Last updated: 2020-01-30Bibliographically approved

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Ferreira Magalhães, Ana CatarinaDe Backer, Jeroen

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Manufacturing, Surface and Joining TechnologyRobotics

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