FeRoll - Friction Element Welding of roll formed HSS, UHSS, and AHSS profiles

Important results from the project

The purpose of the project was to evaluate the joinability of lightweight materials through friction element welding (FEW). The project results showed that the joining method can join the selected materials and create joints with relatively high mechanical strength and with a relatively short process time. The results also showed that adhesive bonding between the components in combination with friction element welding can significantly increase the mechanical strength compared to friction element welding alone.

Expected long term effects

The joining method can provide joints with good mechanical properties between aluminum of different quality, thickness and ductility against high-strength steel of different quality and hardness, even for surface-treated materials with thick coatings and intermediate adhesives. With adhesive, the strength increases significantly. We expect that the process will find numerous applications primarily in the automotive industry where aluminum, including megacastings, must be joined to high-strength steel profiles and press-hardened boron steel.

Approach and implementation

In the project, Bendiro has contributed with the selection of materials for testing and physical specimens and EJOT has contributed with joining equipment and knowledge of the jointing process. The joining has been carried out at EJOT´s development center in Germany in collaboration between RISE and EJOT. Evaluation and analysis of the joined concepts has been carried out by RISE and the report has then been compiled in collaboration between the parties.