Optimized weldbonding for lighter material designs – BONDLIGHT

This project will increase the flexibility and robustness in today’s production by developing a new optimized methodology for weldbonding (combined resistance spot welding (RSW) and adhesive bonding). The new methodology will enable the possibility to manufacture smart, more high-strength and lightweight constructions in existing industrial infrastructures. Both RSW and adhesive bonding have their respective advantages regarding cost, flexibility and robustness. Combining the methods gives improved properties such as strength, stiffness, corrosion resistance and fatigue life in the joint. The main issue for increased use of weldbonding is the decreased weldability in the joint caused by the use of an adhesive bead applied between the metal sheets, which results in decreased electrical conductivity. Hereby thicker materials with lower strength are used today, since these materials are easier to weld with the required quality and process robustness. This leads to increased component weight with up to 30% and thereby increased CO²-emissions. The project will generate new knowledge regarding all in-going parameters in the weldbonding process and develop a methodology for testing and optimization. This will be described in a guideline for optimizing the process for different material combinations, adhesives, sheet thicknesses and surface coatings. The developed methodology will enable more high strength and lightweight designs to be produced in existing industrial infrastructure, in accordance with FFIs strategic roadmap, which in turn will decrease environmental impact and increase the crash-properties in the vehicles of tomorrow. At the same time, an increased flexibility for the manufacturing systems is achieved