Various levels of monitoring are available to ensure the joining point quality. An effective monitoring system is the basis for optimal quality assurance.
In the first level, the parameters and measured values are monitored and evaluated during the process. On the basis of predefined measured parameters and their tolerances, deviations in the process can be determined and conclusions about the quality can be deducted. Due to the reliability and robustness of the process, this level of monitoring works very effectively.
The second level is non-destructive testing after joining. By head angle and head position of the friction element, for example, the correct setting depth and thus the joining quality can be evaluated. Another technical test method would be ultrasonic testing or X-ray. Using these tests, the joining zone can be directly examined for breaks or defects.
The third level represents the destructive test. This examination is mainly applied in the laboratory to carry out parameter identification and technology development. During this process sheet metal combinations, which have been joined with friction element welding, are being separated by means of a chisel, exposed to high force until they get destroyed using shear-, head- and peel tests as well as cross sections done in the joining zone.
The cross-section of the joining zone can be examined for metallurgical and mechanical defects and the hardness in different areas can be tested. The selection of the features to be tested as well as their tolerances are up to the customer’s choice. Our technology experts provide support regarding the selection and definition of these features.