research project Real-time lifetime evaluation of welded joints
Real-time service life evaluation of welded joints under variable thermocyclic loading based on real-time data.
Project name Real-time service life evaluation of welded joints under variable thermocyclic loading based on real-time data.
Acronym Real-time lifetime evaluation of welded joints
Project partner
Grantor
  • Federal Ministry of Economics and Climate Protection
  • AiF Research Association: DVS – Deutscher Verband für Schweißen und verwandte Verfahren e.V. (German Welding Society)
Duration 01.05.2022 – 31.10.2024
Project content
Welded joints represent one of the most important joining techniques in mechanical engineering. Within the scope of the project, novel real-time capable lifetime models for welded joints made of the austenitic steel material 1.4550 for thermomechanical loads with variable amplitudes and plastic deformation are to be developed. For this purpose, component-specific, small-scale substitute models of the weld are used as a digital twin in order to thus describe the service life of the welded joint on the basis of real-time data from operation. To ensure real-time capability, the digital twin consists of a nonlinear finite element model with a sufficiently small number of degrees of freedom. As an alternative approach to the digital twin, extensions of approximate solutions for welded joints are developed.
The methods to be developed have a generic character and are thus transferable to other thermomechanically highly stressed components such as power plant components, gas, aircraft and steam turbines, combustion engines, high-temperature fuel cells and hot forming tools, as well as other materials.
The project has a direct relevance for SMEs involved in manufacturing, non-destructive testing, evaluation and monitoring of welded joints, as well as in accompanying material and sensor-based component testing under operational stresses.