INNODEFAB - INNOvative concepts for lightweight DEsign and FABrication of welded high strength steel structures

Purpose and goal

Targets met; a new lightweight concept for steel sandwich (SSD) was developed and manufacturing and fatigue life evaluated on Demonstrators 2x2 m. Much longer fatigue life was reached than calculated; tests were aborted after 11 Mcycles without fracture. 4 different Demonstrators were produced, in both Stainless and Construction steel. All outperformed. LCC and LCA analysis showed that >20% savings can be reached in material, weight and cost with the SSD. The project also studied new improvement methods for weldments with good results, improved Guidelines and education material.

Expected results and effects

The successful test results for the new lightweight concept with steel sandwich (SSD) will lead to introduction in new products; from floors in heavy vehicles, buses or ships, to bridge decks. TRV will now allow new bridge designs with SSD. The project also studied new improvement techniques for weldments; evaluated influence on fatigue life and built Guidelines. Successful cooperation between project partners and participants in the open workshops will lead to increased use of the improvement techniques in industry, and also increased quality, product life and competitiveness.

Planned approach and implementation

The project was run between Q4 2013 and Q1 2017, lagging behind in Demonstrator testing and final reporting. The project had six work packages and the partners were extended from 13 to 16, with approval from Vinnova. Invited were Exportreform and SONATS (residual stress measurements and HFMI treatment), and Swedish Welding Commission (dissemination). Participating branches were vehicle, bridge, transport, materials, consultancy and research organisations. Cooperation, workshops and project results have been successful, the scope of testing was, however, probably too large.