Automated Joining and Non-Destructive Testing of Tube-Fitting-Joints (AutoFit)

In the AutoFit project, IUL and its partners investigated the mechanical and form-fit joining of aluminum tubes with PEEK components for use in commercial aircraft fuel systems. The focus was on the numerical and experimental process design of electromagnetic forming (EMF) and internal high-pressure forming (IHF). Due to the brittle behavior of PEEK at high strain rates, EMF proved unsuitable, while quasi-static IHF enabled the production of reliable joints. These were tested under tensile loading, and their maximum transferable force was determined. In addition, an automated assembly cell was developed and successfully tested in the laboratory. The results demonstrate significant potential in terms of efficiency, quality, and cost-effectiveness. Digital acquisition of process parameters enhances traceability and quality assurance. Furthermore, non-destructive inline testing methods were advanced, enabling reduced cycle times, material and personnel costs, while also lowering environmental and health risks.

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Weber, F., Lehmenkühler, P., Hahn, M., Tekkaya, A.E., 2022. Joining of metal-thermoplastic-tube-joints by hydraulic expansion, in: Manufacturing Processes; Manufacturing Systems. Presented at the ASME International Manufacturing Science and Engineering Conference, The American Society of Mechanical Engineers, New York, NY, USA. https://doi.org/10.1115/msec2022-84991

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Weber, F., Hahn, M., Tekkaya, A.E., 2024. Joint strength determination by a resistance-based sensor in metal-polymer joining by hydraulic expansion, in: Mocellin, K., Bouchard, P.-O., Bigot, R., Balan, T. (Eds.), Proceedings of the 14th International Conference on the Technology of Plasticity - Current Trends in the Technology of Plasticity. Presented at the International Conference on the Technology of Plasticity, Springer Nature Switzerland, Cham, pp. 27–34. https://doi.org/10.1007/978-3-031-41341-4_4