Ultra-light aluminium honeycomb sandwich panels with high adhesive strengths, friction stir welding and honeycomb manufacturing
IWE Innovativer Werkstoffeinsatz GmbH & Co. KG
GreifswaldNew on Amplifa
About IWE / KEVESOL
IWE Innovativer Werkstoffeinsatz GmbH & Co. KG, based in Greifswald, develops and manufactures ultra-light core sandwich structures made of aluminium honeycomb with metallic or thin CFRP/GFRP face sheets under the KEVESOL brand. The company's in-house bonding process achieves drum peel strengths of over 200 N (industry standard 60–100 N), and over 500 N on demand, ruling out delamination even under maximum loads. The sandwich panels are produced as flat, bent, singly curved and true three-dimensionally curved structures and can be equipped with pull-out-resistant inserts (Helicoil/Ensat thread inserts) as well as integrated cooling channels. In addition, IWE expands aluminium honeycomb as core material, as cutting mats for laser and waterjet cutting, flow straighteners and impact absorbers – up to 14 panels per day, around 2,800 per year. Using a mobile friction stir welding (FSW) system, panels with weld seam lengths of up to 5.6 m can be welded and inserts welded in without destroying the adhesive bond. Customers come from mechanical engineering and vehicle construction, rail transport (monorail), aerospace, and the recreational watercraft sector.
- Site
- Greifswald
- Processes
- Bonding process for aluminium honeycomb with face sheets (KEVESOL), Manufacturing of sandwich panels (flat, bent, singly curved and 3D structures), Friction stir welding (FSW) of KEVESOL panels, Welding-in of inserts in KEVESOL panels (FSW), Production of aluminium honeycomb (expansion), also as cutting mats for laser and, Insert technology (inlays with form fit to face sheets, Helicoil/Ensat thread inserts), Drum peel test (testing of adhesive strength, IWE standard >200 N, adjustable up to >500 N), 3-point bending test on weld seams
- Materials
- Aluminium honeycomb, Aluminium face sheets, CFRP face sheets, GFRP face sheets, Adhesive film, Helicoil thread inserts, Ensat thread inserts, Lithium-ion batteries (mounted via inserts)
- Certificates
- Drum peel test (adhesive strength), 3-point bending test (weld seams)
- Industries
- Mechanical engineering, Vehicle construction, Rail transport (monorail), Aerospace, Watercraft/Sports, Protective technology/armored vehicles
- 01
Expansion of aluminium honeycomb
- 02
Bonding process (KEVESOL) with face sheets
- 03
Insert technology with thread inserts
- 04
Friction stir welding (FSW)
- 05
Testing (drum peel and 3-point bending tests)
Materials & Processes
Aluminium honeycomb
Core material for sandwich panels as well as cutting mats, flow straighteners and impact absorbers.
Aluminium face sheets
Face sheets for flat, bent and curved sandwich panels, also compatible with cooling channels.
CFRP face sheets (e.g. 0.2/0.4 mm)
Thin face layers for additional weight-saving potential and 3D-curved structures.
GFRP face sheets (e.g. 0.2/0.4 mm)
Enable three-dimensionally curved structures of any shape, such as seat shells.
Sites
Greifswald
DEDevelopment and Manufacturing
- Lot size
- up to 14 aluminium honeycomb panels/day
- Materials
- Aluminium, CFRP, GFRP
- Mobile friction stir welding system (FSW, weld length 5.6 m, extendable)
- Automated expanding table for lightweight honeycomb
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Bonding process for aluminium honeycomb with face sheets (KEVESOL)Joining | – | – | – | – | Aluminium honeycomb, Aluminium face sheets, CFRP face sheets, GFRP face sheets |
| Manufacturing of sandwich panels (flat, bent, singly curved and 3D structures)Joining | – | – | – | – | Aluminium, CFRP, GFRP |
| Friction stir welding (FSW) of KEVESOL panelsJoining | – | 5.6 m (extendable in 3 m increments) | – | – | Aluminium |
| Welding-in of inserts in KEVESOL panels (FSW)Joining | – | – | – | – | Aluminium |
| Production of aluminium honeycomb (expansion), also as cutting mats for laser andForming | – | – | – | approx. 14 aluminium honeycomb panels | Aluminium |
| Insert technology (inlays with form fit to face sheets, Helicoil/Ensat thread inserts)Joining | – | – | – | – | Aluminium |
| Drum peel test (testing of adhesive strength, IWE standard >200 N, adjustable up to >500 N)Testing | – | – | – | – | Sandwich structures |
| 3-point bending test on weld seamsTesting | – | – | – | – | Aluminium |
| Cooling channel integration in sandwich panels (coolant in direct contact with face sheets)Joining | – | – | – | – | Aluminium |
2 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Mobile friction stir welding system (FSW system) | – | – | Executable weld length 5.6 m, extendable in 3 m increments | – | Greifswald |
| Expanding table for lightweight honeycomb (automated) | – | – | – | – | Greifswald |
Additional services
Reference customers
Quality
Adhesive strength is tested in the drum peel test (IWE standard >200 N, adjustable up to >500 N); welded seams are examined in the 3-point bending test and drum peel test.
| Evidence | Greifswald |
|---|---|
| Drum peel test (adhesive strength) | |
| 3-point bending test (weld seams) |
History
- 2016
KEVESOL panels shown on lunar lander model at ILA 2016
- 2021
ERDF project KerbaS: sandwich structures with ballistic protection (Programme 2021-2027 MV)
ERDF project LeiFo: lightweight floating bodies and foils for small watercraft (OP MV 2014-2020)