Lightweight and Leakproof Electronic Assembly by Friction Stir Welding in BEV

Purpose and goal: The project has successfully achieved the following set research goals in this feasibility project:

1. Friction stir welding procedure for Al castings (HPDC and sand casting) in different combinations of lap joint configurations are developed through Experimental works. 2. All welds are analyzed by microscopy and mechanical testing. 3. Next generation tools for the process are developed for higher welding speed.

4. Defect-free continuous welds are achieved, which allows to replace fasteners and hence contributing to sustainability to produce cooling plate assembly. Expected results and effects:

The project has successfully produced defect-free welds of different cast aluminium alloys in lap joint configurations. The welds were found sound weld during metallography and mechanical testing. The project resulted in developing next generation welding tools with the help of the project partners.

The new tool tested successfully during the experimental work, and it found promising for future studies, especially welding of aluminium casting where tool wear is significant. Overall, a short route-to-market (end user to subcontractor) for this new welding technology is envisaged. Approach and implementation:

University West led the weld experiments, testing and characterization of aluminium casting plates supplied by Volvo Technology. The welding tools were produced and supplied by the DOF tools, and welding experiments conducted on robotic system at University West. Weld parameters established by evaluating weld surface and cross-section using optical microscopy.

The samples for joint strength testing were supplied by Volvo and results were discussed in detail by all project partners. SKB provided useful insights on weld strength and tools during the project meetings.