Master Thesis, 30 HP: Flexible Robot mounted Refill Friction Stir Spot Welding (RFSSW)

Are you a student eager to apply your theoretical knowledge and fresh perspectives to real-world challenges? At Saab, we believe that innovation thrives on new ideas, and your master thesis project could be the spark that ignites our next technological breakthrough.

Your role

We recognize the immense value that students bring to our company. Your academic rigor, combined with your enthusiasm for cutting-edge technology, allows you to approach problems with a unique and insightful lens. At Saab, you'll have the opportunity to collaborate with experienced engineers and specialists, gaining invaluable practical experience while making a tangible contribution to our growth and development.

Background

Refill Friction Stir Spot Welding (RFSSW) is an advanced joining process that creates localized spot welds without melting the material. RFSSW utilizes the same fundamental working principles of Friction Stir Welding (FSW) but leaves a flush surface without any exit hole. RFSSW has seen significant advancements in recent years, particularly within the aerospace sector, and offers distinct advantages over conventional welding methods by eliminating solidification, gas, fume, filler etc.

The RFSSW joining technique could eliminate the need for large numbers of fastener/screws joints by removing the need for drilling, disassembly, deburring, reassembly, and fastener insertion/removal. Resulting in a sustainable solution to achieve much lighter, robust, and cost-efficient assembly for airframe structures.

As part of an ongoing strategic initiative, Saab has invested in state-of-the-art RFSSW equipment designed and prepared for robotic integration. Starting from Q4 2026, this equipment will be utilized in a fixed test rig for coupon testing to evaluate joining of various materials, including aluminum and fiber reinforced composites.

Description of the Thesis Project

The primary objective of this thesis is to evaluate and enable the transition of the RFSSW equipment from a fixed rigg to a flexible, robot-mounted system. The project will contain a broad technical scope, including:

• The evaluation of various process parameters for RFSSW.
• The development of robot programming and trajectory optimization.
• The design and assessment of fixtures and tooling required for robotic manipulation.
• Solving the practical engineering challenges associated with mounting a high-force welding tool onto a robotic manipulator to increase operational flexibility.

You will work in a close collaboration with Saab Engineers in an ongoing project where other areas of RFSSW are addressed such as mechanical testing and evaluation along with design and manufacturing of a large scale demonstrator.

We provide the support and guidance you need to translate your theoretical knowledge into practical solutions. Join us and become a driving force behind Saab's technological advancements!

This position requires that you pass a security vetting based on the current regulations around/of security protection. For positions requiring security clearance additional obligations on citizenship may apply.

Kindly observe that this is an ongoing recruitment process and that the position might be filled before the closing date of the advertisement.

Your profile

We are looking for one or two motivated students currently pursuing a degree in Mechanical Engineering. You should be in the final stages of your studies and ready to begin your 30 HP master's thesis during the Spring semester of 2027. A strong interest in or prior knowledge of automation and robotics will be considered a significant merit.

Contact information

Jonatan Henschen, Manager

+46 734186710

jonatan.henschen@saabgroup.com

What you will be a part of

Explore a wealth of possibilities. Take on challenges, create smart inventions, and grow beyond. This is a place for curious minds, brave pioneers, and everyone in between. Together, we achieve the extraordinary, each bringing our unique perspectives. Your part matters.

Saab is a leading defense and security company with an enduring purpose, to help nations keep their people and society safe. Empowered by its 28,000 talented people, Saab constantly pushes the boundaries of technology to create a safer and more sustainable world.

Saab designs, manufactures and maintains advanced systems in aeronautics, weapons, command and control, sensors and underwater systems. Saab is headquartered in Sweden. It has major operations all over the world and is part of the domestic defense capability of several nations. Read more about us here.