Frank Ellermann

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Frank Ellermann (born November 7, 1954 ) is a German welding engineer living in Austria .

Professional activities

Frank Ellermann was Head of Welding Technology and Design at Hammerer Aluminum until his retirement at the end of 2019. His focus was on increasing the value of extruded aluminum profiles through welding and mechanical processing. In addition to the MIG and TIG welding process, he used the innovative friction stir welding process to connect extruded profiles to form panels.

Articulated railcar of the Wuppertal suspension railway

One of his most demanding applications was welding the aluminum car bodies of the Wuppertal suspension railway . Since the first FSW machine was commissioned in October 2005, he has developed friction stir welding into a strategic key technology with which automotive components such as a B-pillar for the Audi R8 Spyder and a battery base for an electric car are welded.

In the manufacture of a range extender rotary piston engine from an aluminum alloy produced by powder metallurgy, a friction stir welding process could be used that both avoids gaps in the running area of ​​the sealing elements and enables a defect-free weld seam with properties similar to those of the base material.

For the milling, he used a powerful, user-friendly programming software (Powerful User-friendly Milling Application) for process optimization, with which machining programs can be sent to different machines in order to optimize the path, the tool, the milling path, the clamp management and the bars.

Individual evidence

  1. ↑ Certificate DIN EN 15085-2 certification level CL1.
  2. ↑ F. Ellermann, S. Pommer, G. Barth: Use of friction stir welding in the manufacture of the car bodies for the suspension railway in Wuppertal. DVS Congress: Big welding conference , 15./16. September, Hotel Pullman Berlin Schweizerhof, Berlin.
  3. ↑ Dr.-Ing. Frank Ellermann, Ranshofen, Austria Friction stir welding (FSW) of aluminum components for rail vehicle construction. In: Welding Training and Research Institute Halle GmbH: Joining and construction in rail vehicle construction. Lectures at the 11th symposium "Joining and Designing in Rail Vehicle Construction" in Halle on May 5th and 6th, 2015.
  4. ↑ Frank Ellermann: Manufacture of aluminum welding components for the automotive industry In: Welding and testing technology 09-10 / 2018. Pp. 143-144.
  5. ^ Daniel Schmid: Friction stir welding of aluminum alloys with steels for the automotive industry. P. 36.
  6. ↑ A. Elrefaey, K. Anders, H. Kilian, F. and W. Ellermann Kühlein: Friction Stir Welding of Powder Metallurgy Extruded Al Alloy. Friction stir welding was used successfully to join an extruded powder metallurgy Al alloy without discontinuities, voids, or defects. Welding Journal 2014, pp. 451-457-s.
  7. ↑ Johann Blaha, Michael Steinbauer, Christian Seltenhammer, Peter Schäffler, Kevin Anders, Helmut Killian, Rudolf Gradinger, Josef Reiter, Wolfgang Kühlein, Frank Ellermann, Claudia Weithaler, Tim Dommert, Karl Auer: Innovative manufacturing methods for components of a range extender rotary piston engine. In: Energy-efficient mobility: Opportunities for material and process technology, Ranshofener Leichtmetalltage, 7th LKR-Verlag, Ranshofen; 2012. pp. 172-184.
  8. ↑ High quality aluminum products according to customer requirements.
personal data
SURNAME Ellermann, Frank
BRIEF DESCRIPTION German welding engineer in Austria
DATE OF BIRTH November 7, 1954