Manufacturing involves a variety of production processes whereby semi-finished goods are used to create geometric and functional specific products. Different joining and cutting technologies are employed for this purpose. Process development and advancement are required to cut production costs and achieve product innovations through new lightweight construction concepts, hybrid joints, and functional integrations. The iwb Research Team "Joining and Cutting Technologies" specializes in the analysis and further research of joining technologies via fusion and pressure welding processes. Activities focus on the theoretical and experimental design of processes, the integration of systems technology, and the implementation and execution of system concepts. This work is accompanied by the numerical mapping of processes by thermo-mechanical simulations. In the research group, strategies are also developed for the qualification of innovative technologies and the implementation of processes into production operations. The research work is divided between two fields:  "Laser Manufacturing Technologies" and "Friction Welding."

With high-power laser beam sources, the Research Field Laser Manufacturing Technologies" creates new application possibilities for the macro-material processing of metallic substances. The focus in this case is on the application-oriented optimization of systems and process technology for laser beam cutting and welding processes. Another field of activity is the design of sensor technology. The Scout Sensor was one of the first welding seam position sensors ever produced. Today's research focuses on in-situ sensor concepts for quality control of welding seams, whereby the alloy composition in the welding seam is monitored online. In another field of research, the high-brilliance radiance of the latest laser beam sources enables a transfer of conventional laser processes to remote applications. Laser radiation also holds risks for people and equipment. The iwb undertakes to ensure protection against laser radiation with its development of new laser safety concepts. By combining and coupling laser radiation with conventional, well-established manufacturing methods (e.g., milling), synergy effects are utilized and new production potential is realized. In the field of simulation, strategies are developed for the component-based, structure simulation of thermal manufacturing processes and also qualified for industrial use.

In the Research Field "Friction Welding," the iwb deals with, among other things, friction stir welding (FSW). This process allows for the firm joining of metals that are conventionally considered as non-fusion weldable. In particular, FSW is suited for high-quality welding of aluminum and its alloys. The process requires high process forces, which often have to be provided by specially designed, stiff welding machines. To provide sufficient flexibility for facilities, the iwb is attempting to implement FSW in conventional industrial applications (CNC machining centers and high payload robots). To fully exploit the potential in this system, the iwb is investigating both conventional and new tool designs. In addition, the FSW activities include the welding of new composite materials. Rotational friction welding is investigated in addition to FSW. For these purposes, the iwb developed and built its own facility for inertia friction welding. Experiments are carried out with this facility. Thus, the iwb contributes to the continuous improvement of process simulation and systems engineering.

The members of the Research Team "Joining and Cutting Technologies" work together with other researchers in the Collaborative Research Center "Integration of Forming, Cutting, and Joining for the Flexible Production of Lightweight Frame Structures" of the German Research Foundation (DFG). Here, the fusion of aluminum by hybrid bifocal laser beam welding (BHLS) and FSW is studied, and the structure simulation of these processes is investigated. Furthermore, researches collaborate with the Department for Data Processing in the Excellence Cluster CoTeSys on the development and study of algorithms for data collected during the quality control stage of laser beam welding processes.