Bobbin Tool and Process Monitoring for FSW for Lightweight Applications (FSW4Lightweight)
This project aims at a simulation-based development of a bobbin tool and a process monitoring system for the friction stir welding (FSW) of lightweight profiles 30mm for railway applications. The extended applicability and improved reliability of FSW allows to realise unexploited weight reductions.
Description
Within the scope of the EUREKA Lightweight Call, the FSW4Lightweight project focuses on
- the development of a bobbin tool for thick joints up to 30mm, and
- an online process monitoring system for friction stir welding (FSW) of lightweight profiles for railway applications.
The Swiss-Austrian research consortium includes STADLER Rail, Rapid Technic, Stirtec, and an interdisciplinary expert group from ZHAW and TU Graz.
FSW using a bobbin tool (BT-FSW) is ideal for joining large extruded hollow chamber profiles with limited accessibility, reducing process forces. Systematic welding experiments and process simulation are used to develop a BT-FSW tool and process up to 30mm thick weld joints, allowing significant weight reductions by eliminating support structures needed for standard MIG or FSW.
As FSW is pushed for higher productivity and profitability, the risk of welding defects or tool failure rises. To meet the quality requirements of the railway industry, a process monitoring system is developed to detect defects and tool failure during joining, improving the reliability and profitability of FSW.
Key data
Projectlead
Deputy Projectlead
Project team
Project partners
Technische Universität Graz / IMAT Institute of Materials Science, Joining and Forming; Stadler Rail AG; STIRTEC GmbH; Rapid Technic AG
Project status
ongoing, started 05/2025
Institute/Centre
Institute of Materials and Process Engineering (IMPE); Institute of Mechanical Systems (IMES)
Funding partner
Eureka
Project budget
1'836'661 EUR
