SPP 1640:  Joining by Plastic Deformation

• Subject Area: Mechanical and Industrial Engineering
• Term: from 2012 to 2019
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 199763459

Today’s social and ecological conditions require extensive efforts to facilitate the efficient use of energy and resources. Regarding these circumstances, design criteria of technical products consider the possibilities of consequent lightweight construction and smart structures. Both approaches lead to hybrid components consisting of different materials. A sound combination of these materials offers excellent properties regarding functionality, mass density, safety and consumption of energy and resources. Joining techniques based on plastic deformation of at least one component offer great potential for a reduction in the use of energy and natural resources to produce multi-material joints. Though, a substantial gap of knowledge exists regarding the joining techniques, their design, destructive and non-destructive testing methods and the specific characteristics of the particularly relevant joining mechanisms. The Priority Programme aims for an interdisciplinary gain of knowledge regarding the underlying mechanisms in the processes of joining by plastic deformation as well as methods for the design of both joining processes and joint properties. The enhanced knowledge of the joining mechanisms is supposed to lead to the design of new or improved joining techniques, design criteria for joints, new products and to an extended use of hybrid components in modern products. The overcoming of the mentioned deficits in existing processes and the development of joining techniques are focussed by this Priority Programme. Knowledge gaps exist regarding the joining mechanisms, the achievement of the required plastic strain of hardly formable or brittle materials, the predictability of the joint strength with theoretical models and the field of non-destructive testing of the joints. In order to fill these gaps, developments on the fields of forming, measuring and controlling engineering, plastic mechanics, chemistry and mathematics are to be linked within this programme.

• DFG Programme: Priority Programmes

Projects

• Finite element analyses and simulation of the failure of short-fiber reinforced thermoplastics and aluminium blanks by clinching (Applicants Behrens, Bernd-Arno ;  Rolfes, Raimund )
• Hole Roller Clinching of Multi-Material-Lightweight Joints (Applicant Volk, Wolfram )
• Hybrid flat-clinching of renewable raw materials (Applicant Awiszus, Birgit )
• Investigation and enhancement on bonding by cold bulk metal forming processes (Applicants Groche, Peter ;  Rohwerder, Michael )
• Investigation of the formation mechanisms of the bonding zone in impact welding (Applicant Groche, Peter )
• Joining by high speed forming by laser induced shock waves (Applicant Vollertsen, Frank )
• Joining of blanks with electrochemical support (ECUF) (Applicants Grundmeier, Guido ;  Homberg, Werner ;  Maier, Hans Jürgen )
• Laser- und ultraschallunterstütztes Clinchen von hochfesten Stahl/Aluminium-Mischverbindungen (Applicants Füssel, Uwe ;  Keßler, Olaf ;  Wanner, Martin-Christoph )
• Local microstructural evolution, interfacial integrity and rate effects associated with modern joining processes using plastic deformation (Applicant Wagner, Martin Franz-Xaver )
• Magnetic pulse welding: Targeted manipulation of weld seam formation (Applicants Beyer, Eckhard ;  Tekkaya, A. Erman )
• Mechanical joining of dissimilar materials by shear clinching processes without pre-punching (shear clinching) (Applicants Merklein, Marion ;  Meschut, Gerson )
• Mechanisms in Joining of Dissimilar Materials using Friction Stir Welding (Applicants Haider, Ferdinand ;  Zäh, Michael Friedrich )
• Multiscale modelling of joining processes taking account of the thermomechanical-chemical behavior in the boundary layer (Applicant Reese, Stefanie )
• Multiscale modelling of joining processes under consideration of the thermo-mechano-chemical behaviour in the interface (Applicant Reese, Stefanie )
• Realization of Al/High Strength Steel: Joints by Ultrasound Supported Friction Stir Welding - Process and Robustness, Mechanical Properties using Destructive and Non-Destructive Testing Methods, Microstructure, Corrosion, and Joining Area Integrated Corrosion Protection (Applicants Fuerbeth, Wolfram ;  Wagner, Guntram ;  Wolter, Bernd )
• Robust Scaling of Roller Clinching Processes (Applicant Volk, Wolfram )
• Roll bonding materials with with highly unequal material strengths - Analyses of the joining mechanism and modeling new manufacturing procedures (Applicant Hirt, Gerhard )
• Simulation-aided development and qualification of a novel Thermoclinch joining technology for multi-material design with textile-reinforced thermoplastic composites (Applicant Gude, Maik )
• Studies on the reproducibility of the magnetic pulse welding in the case of an asymmetric impact (Applicant Böhm, Stefan )
• Studies on the reproducibility of the magnetic pulse welding in the case of an asymmetric impact (Applicant Böhm, Stefan )
• Verfahrensentwicklung zur Rohr-Massivumformung beim Quer-Fließpressen von Flanschen und Bunden mit und ohne Außenkontur (Applicant Liewald, Mathias )

• Spokesperson: Professor Dr.-Ing. Peter Groche
• Participating Persons: Professorin Dr.-Ing. Birgit Awiszus; Professor Dr.-Ing. Bernd-Arno Behrens; Professor Dr.-Ing. Eckhard Beyer; Professor Dr.-Ing. Stefan Böhm; Professor Dr. Andreas Erbe; Professor Dr.-Ing. Wolfram Fuerbeth; Professor Dr.-Ing. Guido Grundmeier; Professor Dr.-Ing. Maik Gude; Professor Dr. Ferdinand Haider; Professor Dr.-Ing. Gerhard Hirt; Professor Dr.-Ing. Werner Homberg; Professor Dr.-Ing. Hans Jürgen Maier; Professorin Dr.-Ing. Marion Merklein; Professor Dr.-Ing. Gerson Meschut; Professorin Dr.-Ing. Stefanie Reese; Professor Dr.-Ing. Raimund Rolfes; Professor Dr.-Ing. A. Erman Tekkaya; Professor Dr.-Ing. Eckart Uhlmann; Professor Dr.-Ing. Wolfram Volk; Professor Dr.-Ing. Frank Vollertsen; Professor Dr.-Ing. Guntram Wagner; Professor Dr.-Ing. Martin Franz-Xaver Wagner; Dr.-Ing. Bernd Wolter; Professor Dr.-Ing. Michael Friedrich Zäh