Fastener-less Joining Technologies for High Performance Hybrid

Fastener-less Joining Technologies for High Performance Hybrid Composites-Metal Structures (FALCOM)
Project coordinator: Dr. Conor McCarthy (conor.mccarthy@ul.ie)
Coordinating Institution: MSSI (Materials & Surface Science Institute), University of Limerick, Ireland.
Call Identifier: FoF-12-2015, Topic: Industrial technologies for advanced joining and assembly processes for
multi-materials (see Appendix I for call fiche)
Technology Readiness Level (TRL): 5-7
Proposal No. 679199
Status: Currently under review
Background: Without the ability to make strong and durable connections between composites and metals it
would not be possible to produce the many different items upon which we all rely on in our everyday lives,
from the very large (buildings, aircraft, trains and bridges) to the very small (medical implants and electronic
devices). This project will develop a brand new approach to join composites to metals that does not require
any mechanical fastening. Such an approach would be highly advantageous to manufactures and consumers in
both the assembly and disassembly of components, and will open up new business opportunities for Europe.
Rational: Joining composites to metals is a key enabling technology that will underpin the development, and
realisation, of future high-performance hybrid structures, from ultra-modern composite aircraft, light-weight
electric cars and ship hulls, to state-of-the-art renewable energy structures, such as wind and wave energy
turbine blades. Joining composites to metals presents many scientific challenges, due mainly to a significant
mismatch in their thermal expansion coefficients and their vastly different surface chemistries. Mechanical
fastening has, thus, been the technology of choice for designers, but this technology is very inefficient and
expensive, and so novel fastener-less joining approaches are urgently required.
Aims and Objectives: The main aim of this project is to develop a state-of-the-art fastener-less joining
technology. This will be realised by designing novel interlocking surface profiles that will be both cast and laser
machined into mating surfaces, to form hierarchical structured surfaces that will mechanically interlock in
shear when brought together. New fully reversible adhesives will be developed to bond and seal these
interlocked surfaces, to result in highly durable joints that that will be fully reversible (by subjecting them to
focused electromagnetic waves). This project will, thus, provide designers with new tools to integrate
reversibility into their structures, so that components can be dissembled easily for repair, replacement or for
recycling. The availability of this technology would be completely novel, and cutting-edge, and would
represent a paradigm shift in the way joints, and their surrounding structures, will be designed and
manufactured in the future. The following table highlights the key advantages of the proposed technology,
Demonstration of FALCOM’s cutting-edge approach
Joint Type
High Joint
High
Efficiency
Reliability
Bolted
Bonded
CoMeld™
FALCOM
Easy to
Assemble
Easy to
Disassemble
No Weight
Gain
The high level objectives of the project are thus to,
1. Design and optimise novel fastener-less joining technologies for joining composites to metals;
2. Develop high throughput manufacturing tools, with scalability, to manufacture these joints;
3. Evaluate life-cycle performance of these new joints including joint reversibility protocols;
4. Demonstrate these joints on real automotive and aerospace composite to metal structures under
simulated operational loads, with full cost-benefit analysis.
Project Impact
The value added by manufacture and application of Joining technology in Europe amounted to around €100bn
in 2010 and over 2.5M employees were connected with this added value. This statistic clearly highlights the
impact potential for developments in joining science. Fastener-less, reversible, joining technologies for joining
composites to metals has the potential to revolutionise the way joints will be designed and manufactured in
the future. Joining composites to metals is a key enabling technology that will allow industries to integrate
composite components into their existing and future products. The joint is where part integration occurs, and
normally presents the greatest technical challenges to designers, due to mismatch in mechanical properties
between the joined members. The joint, in itself, adds cost and complexity to a structure, but cannot be
avoided due to assembly constraints, the need for part repair and replacement and the need to recycle
structures. However, the joint, if designed correctly, can add significant value to products, as it normally
controls the overall mass of the surrounding structure. Hence, more efficient joints will ultimately lead to
reduced mass components, and therefore cost and weight of the surrounding structure, which are identified
as key requirements to achieve manufacturing competitiveness in Europe. This project will provide industry
with new tools to integrate composites into present and future high-end European products, and such
activities are highlighted as key drivers to transform the European manufacturing industry into a knowledgebased sector. The proposed joining approach is a strong concept at a Technology Readiness Level (TRL) of
approximately 2, and is currently funded by a €1.35M Science Foundation Ireland grant to bring it to TRL 4-5.
In Horizon 2020 FoF12, the project will be taken from TRL4-5 to TRL 7 by technology validation in automotive
and aerospace environment, leading to prototype demonstration under operational conditions in these
environments. A business plan will be developed and implemented.
APPENDIX I: Call Description
Topic: Industrial technologies for advanced joining and assembly processes for multi-materials
FoF-12-2015
Specific challenge: Multi-material design of components and structures provides an opportunity to
develop products which are able to operate under more exigent requests demanded by market and
society such as increased strength-to-weight ratio, multi-functionality, highly aggressive environments
and low carbon footprint. By smart use of adequate joining technologies, and the incorporation of multimaterial design into the assembly chain, the final product performance can be improved. This is
particularly relevant when high cost, scarce or hazardous materials are involved.
Scope: Traditional joining leads to loss of the performance that materials offer in their final product,
because of modifications in composition and properties or geometric distortion. Improved, new or hybrid
joining and assembly processes are therefore needed to be developed for specific combinations of
designs and materials, in combination with flexible and automated non-destructive inspection
technologies, in order to overcome the mentioned limitations. Technologies to be addressed can be
welding processes, bonding using adhesives, mechanical joining or any other joining process. The novel
joining integration capabilities will feature a high degree of process automation and quality control and
they will make use of sustainable manufacturing practises. Assembly and disassembly efficiency, product
quality, recycling and cost targets will also be considered. While the focus will be on demonstrating the
technologies, R&D activities supporting the integration and scale-up are expected as well.
Demonstration activities should focus on all of the following priorities:
- Joining and assembly processes that will lead to maximise performance of the joints and/or to facilitate
recycling, based on a deep understanding of the cause-effect relationships as well as of materials process
interactions.
- The implementation of numerical simulation techniques, including computational multi-scale modelling,
which will lead to a better understanding of the considered joining processes as well as product
development along all its different phases.
- The development of high efficient, cost-effective and flexible surface condition solutions (e.g. surface
modification, thermal treatments, gap avoidance) to provide joints with the maximum performance.
- The implementation and set up of reliable, efficient and automated non-destructive inspection
techniques for joint quality evaluation, together with in-situ monitoring and control systems for critical
variables of the joining operations that will guarantee reliable, robust and safe production conditions in
industrial environments.
At least one prototype or pilot implementation in pre-industrial settings aiming at demonstrating the
scalability should be delivered before the end of the project as a proof of concept.
For this topic, proposals should include an outline of the initial exploitation and business plans. Wherever
possible, proposers could actively seek synergies, including possibilities for cumulative funding, with
relevant national / regional research and innovation programmes and/or European Structural and
Investment Funds in connection with smart specialisation strategies. Exploitation plans, outline financial
arrangements and any follow-up should be developed during the project.
Activities expected to focus on Technology Readiness Level 5-7. A significant participation of SMEs with
R&D capabilities is encouraged.
The Commission considers that proposals requesting a contribution from the EU between EUR 4 and 7
million would allow this specific challenge to be addressed appropriately. Nonetheless, this does not
preclude submission and selection of proposals requesting other amounts.
Expected impact:
Application of multi-material design to products through the developed joining and assembly processes
will bring:
· At least 20% decrease in the consumption of high cost and critical materials.
· At least 30% improvement of the product performance, without increasing the final price.
· A higher level of automation and lower production times compared to current technologies.
Type of action: Innovation Actions.