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Charakterisierung und Detektion von Tunneldefektion in FSW-geschweißten Aluminiumblechen mittels Blocklast-Ermüdungsrisswachstumsversuchen

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Description

Reibrührschweißen (FSW) ist eine etablierte Technologie zur Fertigung metallischer Flugzeugrümpfe aus Aluminium. Trotz hoher Prozesskontrolle treten entlang der Schweißnaht vereinzelt Defekte auf, deren Ursachen bislang nicht vollständig geklärt sind. Diese Fehler können die strukturelle Integrität der Verbindungen erheblich beeinträchtigen. Datengetriebene Ansätze wie maschinelles Lernen bieten neue Möglichkeiten, komplexe Ursache-Wirkungs-Zusammenhänge zwischen Schweißparametern, Nahtqualität und mechanischen Eigenschaften systematisch zu analysieren. Hierfür sind jedoch umfangreiche, qualitativ hochwertige und präzise gelabelte Datensätze erforderlich. Der vorliegende Beitrag adressiert diese Herausforderung und konzentriert sich auf die Entstehung des sogenannten Tunnel-Schweißfehlers. Dieser tritt als streifenartige Hohlräume am Rand der Schweißnaht auf, wirkt als scharfer Rissinitiator und reduziert die Ermüdungsfestigkeit der Verbindung deutlich. Zur gezielten Erzeugung und Untersuchung von Tunneldefekten werden Bleche mit lokal variierter Vorschubgeschwindigkeit verschweißt. Daraus entnommene Ermüdungsproben lassen sich über einen Lochmuster-Binärcode eindeutig auf ihre Entnahmeposition und die lokalen Schweißparameter zurückführen. In einem ansteigenden Blocklastversuch wird das Ermüdungsrisswachstum nahe dem Schwellwert dKth untersucht, wodurch Tunneldefekte auf der Bruchfläche sichtbar werden, da große plastische Verformungen durch das niedrige dK vermieden werden. So können die Defekte mit optischen Algorithmen automatisiert erkannt und den lokalen Schweißparametern zugeordnet werden. Dies ermöglicht eine systematische Analyse der Beziehungen zwischen Schweißprozessparametern und der Entstehung von Tunneldefekten.

Reference: BR-2026-695

Title: Charakterisierung und Detektion von Tunneldefektion in FSW-geschweißten Aluminiumblechen mittels Blocklast-Ermüdungsrisswachstumsversuchen
Author(s): F. Paysan, E. Breitbarth
DOI: 10.48447/BR-2026-695
Event: 58. Tagung des DVM-Arbeitskreises Bruchmechanik und Bauteilsicherheit – Tagung 2026
Year of publication: 2026
Publication type: conference paper (PDF)
Language: German
Keywords: Reibrührschweißen (FSW),Tunnelfehler,Ermüdungsrisswachstum,Fraktografie

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Experimentelle Rissfortschrittsuntersuchungen an einem hyperelastischen Polyurethan-Klebstoff mit einem optimierten Versuchsverfahren

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€23.36

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Author(s): S. Henschel, L. Krüger

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€23.36

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Editor(s): A. Ricoeur

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58. Tagung des Arbeitskreises Bruchmechanik und Bauteilsicherheit

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