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Global trends are forcing industry to manufacture lighter, safer, more environmentally, more performant and cheaper products. In the automotive industry, weight reduction is pursued and in this regard, lightweight materials such as composites offer the most suitable solution due to their considerably lower density. In view of this, multi-material designs exploit the material with desired properties for each part of the automotive component. However, the need for the next generation of novel hybrid metal-composite components brings along major challenges regarding the joints between different material types. This is the driving force behind the MetalMorphosis research project, which was carried out at the Belgian Welding Institute in collaboration with 8 European research and industrial partners.
This article first presents a short overview of the objectives targeted in the MetalMorphosis research project. Subsequently, the joining design concepts developed and research related to the hybrid metal-composite tubular and sheet joints using the electromagnetic pulse technology, will be addressed. Finally, the development of a brake pedal and a shock absorber, both consisting of metal-composite hybrid components, is highlighted.
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Het project MICROSOUD provides service and knowledge to companies about the modern micro welding technologies and associated quality control.
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Did you already had to deal with galvanic corrosion?
When two different materials come into contact with each other, the least noble material will undergo accelerated degradation in an aggressive environment. This phenomenon is called galvanic corrosion. In the figure below, you can see for example an accelerated degradation of the aluminium that is joined to a copper tube.
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The Belgian Welding Institute will start up a research project to demonstrate the feasibility of quality control using systems for inline, real time defect detection during welding.
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Mainly on account of the automotive industry, stronger steel grades and sheet materials consisting of galvanised steel with organic coatings are being developed. The data about the weldability of these materials is not always up-to-date or available. Companies lose the overview regarding materials because of the fast developments.
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Magnetic pulse welding is a new, very innovative but nearly unknown production process. The working principle of the welding process is based on the use of electromagnetic forces to deform and to weld workpieces. Since this sophisticated welding process doesn't use heat to realise the weld, it offers important advantages with regard to the conventional welding techniques!
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SOUNDWELD investigates a new promising real-time non-destructive examination technique for welding processes, based on acoustic emission during the weld cycle. The acoustic emission technique is based on the detection and conversion of high-frequency elastic waves into electrical signals. Acoustic emission monitoring (AEM) is currently being used for the surveillance of industrial processes or structures. In this project, the application of this technology is expanded towards welding processes.
