FrictionHarmonics · Project

Automated Scanner That Catches Invisible Welding Defects in Aircraft and Car Parts

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Imagine gluing two pieces of metal together so perfectly that the joint looks flawless — but there's a hidden crack inside that you can't see or feel. That's called a "kissing bond," and it's the Achilles' heel of a cutting-edge welding technique used by Boeing and car makers. This team built an ultrasonic scanner that finds these invisible defects — even ones smaller than 0.3mm — with 100% accuracy. Think of it like a medical ultrasound, but for metal joints in airplane wings and car bodies.

By the numbers

60%

Cost saving achieved by Boeing using friction stir welding

73%

Reduction in manufacturing time with FSW

€1.6 billion

Potential manufacturing cost savings over 20 years

€1.9 billion

Potential fuel savings over 20 years

2 million tons

CO2 reduction potential over 20 years

0.3mm

Minimum kissing bond size detected with 100% accuracy

100%

Detection accuracy for kissing bonds under 0.3mm

€33.44m

Projected gross cumulative revenue over 5 years after launch

215

New jobs projected over 5 years after market launch

The business problem

What needed solving

Friction stir welding saves aerospace and automotive manufacturers massive amounts of money and time — Boeing reported 60% cost savings and 73% faster manufacturing. But a hidden defect called a "kissing bond" is invisible to conventional inspection, forcing manufacturers to limit their use of FSW out of safety concerns. This leaves an estimated €1.6 billion in manufacturing savings and €1.9 billion in fuel savings on the table over the next 20 years.

The solution

What was built

The consortium built FrictionHarmonics — an automated nonlinear ultrasonic scanning system that detects kissing bonds smaller than 0.3mm with 100% accuracy. The system was designed for integration into complete FSW production lines, combining Vermon's ultrasonic transducers with RISE's signal processing algorithms and IKH's operator interface.

Audience

Who needs this

Aerospace OEMs and tier-1 suppliers using friction stir welding on aluminum structuresAutomotive manufacturers adopting FSW for lightweight aluminum body panelsFSW equipment manufacturers wanting to offer integrated quality assuranceNDT service companies expanding into advanced weld inspectionRailway and shipbuilding companies using aluminum FSW joints

Business applications

Who can put this to work

Aerospace manufacturing

enterprise

Target: Aircraft component manufacturers and OEMs using friction stir welding

If you are an aerospace manufacturer relying on friction stir welding for fuselage or wing panels — this project developed an automated ultrasonic scanner that detects kissing bonds smaller than 0.3mm with 100% accuracy. Boeing already achieved 60% cost savings using FSW, but hidden defects limit wider adoption. This scanner removes that barrier, unlocking the full potential of FSW in your production lines.

Automotive manufacturing

enterprise

Target: Automotive OEMs and tier-1 suppliers welding aluminum components

If you are an automotive manufacturer working with aluminum alloys and looking to cut weight and production costs — this project built an inline inspection system for friction stir welded joints. FSW can reduce manufacturing time by 73%, but fear of undetectable kissing bonds holds back adoption. This scanner integrates into your production line and catches defects that conventional inspection misses.

Non-destructive testing (NDT) services

any

Target: NDT service providers and quality assurance companies

If you are an NDT service provider looking to expand your capabilities — this project created a commercial-grade nonlinear ultrasonic inspection system specifically designed for friction stir welds. With aerospace and automotive industries projected to save €1.6 billion in manufacturing costs through wider FSW adoption, demand for reliable kissing bond detection is growing. This technology fills a gap that conventional ultrasonic testing cannot address.

Frequently asked

Quick answers

What does this system cost and what's the pricing model?

The project requested a €2.2m grant to finalize the commercial version. Specific unit pricing is not disclosed in the project data. The consortium projected €33.44m in gross cumulative revenue over 5 years after market launch, suggesting a high-value industrial equipment pricing model.

Can this work at industrial production-line speed?

Yes, the system was designed specifically for integration into complete FSW production lines. The project's final goal was to validate performance in a real production environment. The consortium includes Coskunoz, a leader in FSW machinery with commercial presence on 4 continents, ensuring industrial-scale compatibility.

Who owns the IP and can I license this technology?

The consortium is led by Vermon SA (France), a developer of nonlinear ultrasonic transducers. IP is likely shared among the 5 consortium partners under standard EU grant agreements. Contact the coordinator for licensing terms and commercial availability.

How accurate is the defect detection?

Based on the project data, the system detects kissing bonds of less than 0.3mm in diameter with 100% accuracy. This was validated in a relevant environment before the project started, and the EU-funded phase aimed to certify and validate in full production conditions.

What materials and welding types does it work with?

The system is designed specifically for friction stir welded aluminum alloys. FSW is the target application, as kissing bonds are a defect unique to this welding technique. Based on available project data, extension to other materials is not explicitly mentioned.

Is this system certified for aerospace use?

Certification was one of the project's stated goals — specifically to finalize the commercial version, certify it, and validate in a complete production line. The project ended in May 2021. Current certification status should be confirmed with the coordinator.

What's the expected return on investment?

The consortium projected €33.44m in gross cumulative revenue and €13.83m in profit over 5 years after market launch, along with 215 new jobs. For end users, the broader industry impact is estimated at €1.6 billion in manufacturing cost savings and €1.9 billion in fuel savings over 20 years through wider FSW adoption.

Consortium

Who built it

This is a tightly focused, industry-heavy consortium with 4 out of 5 partners from industry (80% ratio) and zero universities — a clear signal this is about commercialization, not academic research. The coordinator Vermon SA (France) makes the ultrasonic transducers, RISE (Sweden) handles signal processing algorithms, IKH (Greece) builds the human-machine interface, Coskunoz (Turkey) brings FSW machinery expertise with commercial presence on 4 continents, and TWI (UK) is the research institute that originally invented friction stir welding itself. The consortium spans 5 countries and covers the entire value chain from sensor hardware to production-line integration, with 2 SMEs driving the commercialization.

VERMON SACoordinator · FR
RISE RESEARCH INSTITUTES OF SWEDEN ABparticipant · SE
COSKUNOZ KALIP MAKINA SANAYI VE TICARET ANONIM SIRKETIparticipant · TR
IKNOWHOW SAparticipant · EL
TWI LIMITEDparticipant · UK

How to reach the team

Vermon SA (France) — ultrasonic transducer manufacturer. Use Google AI Search to find coordinator contact details.

Order a report on this consortium See VERMON SA profile →

Next steps

Talk to the team behind this work.

Want to connect with the FrictionHarmonics team about licensing or integration into your production line? SciTransfer can arrange a direct introduction to the right person in the consortium.

Order a report on this topic More in Manufacturing & Industry 4.0