Robust mechanical joining of cast aluminium components (RobuCap)

Important results from the project

RobuCAP resulted in several important results. Extensive material characterization showed that porosity and microstructural variations have a significant impact on the quality of the joints. Metoden PCT proved to be particularly efficient in evaluating materials. Simulations were used to predict jointing and had good agreement with experiments but emphasized the need for model refinement. The project also investigated the possibility of disassembly and reassembling of joints for circularity.

Expected long term effects

RobuCAP is expected to have several long-term impacts that could have major implications for the automotive industry and circularity. Firstly, the increased understanding of mechanical joining processes for cast aluminum components will lead to more robust and predictable manufacturing methods. This in turn will lead to increased robustness against new materials such as recycled aluminum. The results of the disassembly and reassembly also showed practical routines that can be used in industry.

Approach and implementation

The project was done as a collaboration between several parties; Volvo Cars, Atlas Copco, BTM Scandinavia, Tucker and RISE. The project was structured in several work packages, each focused on different aspects. The project was largely carried out in collaboration between several industrial partners, where Volvo Cars contributed relevant test material and the equipment suppliers contributed physical joint testing. RISE was responsible for, among other things, coordination, analysis, and results.