Download - Agenda - wiki.aalto.fi
1
The Solid State Welding
and Processing Techniques
January 2016
Department of
Mechanical Engineering
* ContactsAddress: P.O. Box 14200, FI-00076 Aalto, FinlandVisiting address: Puumiehenkuja 3, [email protected] ; Skype: fsweldone
Professor Pedro Vilaça *
Materials Joining and NDT
1Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Agenda
Solid state weldingo Classification
o Technological and historical scope
o Joining mechanisms
Overview of Solid State Welding and Processingo Techniques and variants
Friction Stir Weldingo Fundaments
o Industrial applications
o Friction stir welding variants
o Friction stir based processes
2Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
AGENDAOverview of Solid State Welding Processes
High Frequency Welding
Flash Welding
Stud Welding
Cold Pressure Welding
Diffusion Welding
Ultrasonic Welding
Explosion Welding/Cladding and Cutting
Friction Based Technology
3Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
AGENDAOverview of Friction Based Technology
Friction Extrusion
Friction Hydro Pillar
Friction Riveting
Friction Rotary Welding
Friction Linear Welding
Friction Surfacing
Friction Stir Welding
Friction Stir Welding Variants
Friction Stir Based Processes
4Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
AGENDAOverview of Friction Stir Welding Variants
Bobbin-Tool
Static Shoulder
Re-Stir
Dual Rotation
Twin-Stir
Ras-Stir
Skew-Stir
Com-Stir
5Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
AGENDAOverview of Friction Stir Based Processes
Friction Stir Processing
Friction Stir Channelling
Friction Stir Microforming
Friction Stir Embossing
Friction Stir Spot Welding
Friction Spot Welding
Near-Net Shaped
2
6Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State Welding
and Processing Technologies
Solid State Welding
Technological Scope
Classification
7Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State WeldingClassification
Welding Process
Classification
Brazing and Soldering No fusion of Base Material components which are
joined by inserting melted Filler Metal in the overlap joint configuration based on capillarity and diffusion
Fusion Welding Includes local fusion of Base Material proceeded by
solidification with/without application of mechanical energy and with/without Filler Metal
Solid State Welding Joining is obtained by solid state joining mechanisms In some processes, superficial melting layer is
produced to then be expelled during forging Flash around weld zone is usual
Note: There are (many) others possible classifications
8Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State WeldingForging Lead the Way
Techniques based on Solid State Welding and Processing are in
permanent advance since many centuries ago resulting
nowadays in some of the most significant progresses in
The Joining Technology (e.g. Friction Stir Welding)
Bear in mind that
“Advanced (Production) Technology”
does include
“Solid State Welding and Processing Techniques”
9Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State WeldingSome Significant Advantages
Reduction of manufacturing costs:
Reduction of energy consumption
(use less and has a higher energy efficiency)
No consumables in most of applications
(e.g. filler material, shielding gases)
Equipment simple and easily automated which do not require
specialized/high skill operators
High productivity, with results easily reproducible
Allow welding materials difficult or impossible to weld by fusion
resulting in joints with excellent mechanical properties (matching BM)
Typically these are all environmentally clean/friend processes
(e.g. without fumes or radiation emission)
In aggressive environments for humans, allow remote operation and
process control
10Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State Welding
and Processing Technologies
Solid State Welding
Joining Mechanisms
11Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Joining Mechanisms…Activated During Solid State Welding
Aproximation to Interatomic
Distances of Equilibrium
Diffusion
Clinching
Atomic bonding at joining
materials interfaces
Bonding over an interferential layer
which can reach up to
continuous metallic conditions
Mechanical interference
3
12Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State WeldingEnergetic Activation of Joining Mechanisms
Mechanical
Energy
Heat Energy
Liquid joining interface:High-frequency; Flash; Stud
Welding
Friction; Ultrasonic;Explosion; Diffusion
Welding
Cold Welding
Fusion of a nugget in close die pressured zone:
Resistance Welding
Fusion with no pressure:e.g.: SMAW; GTAW; GMAW; FCAW; SAW ; Laser Welding
Note: Sometimes wrongly classified as
fusion welding!
… these techniques are based on solid state
joining mechanisms!
13Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State WeldingEnergetic Activation of Joining Mechanisms
Expressed as a ternary diagram
In all solid phase welding operations, the controlling parameters are:
1) Time
2) Temperature
3) Deformation
14Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Joining Mechanisms…Activated During Solid State Welding
Mechanical
Energy
Heat Energy
DifusionInterfacial
Atomic bondingInterfacial
Diffusion + Atomic bondingVolumic
w/ visco-plastic material flow
15Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Joining MechanismsGeneration of New Surfaces Chemically Active
Production of New Surfaces by Plastic Deformation:
At room temperature: Highly ductile materials
(typically FCC metallic microstructure)
At high temperature: Most of the engineering materials
Cleaning is Typically Not Enough…
…But is Mandatory and/or Suggested for solid state processes
where no liquidification and/or flash is produced
Original surfaces need to be removed out from final joining interface:
Surface Layer Liquidification + Expelled out
Production of Flash (more or less massive + may or not need to be
removed from weld joint)
Fine Disruption + Dissemination of original superficial particles
within joint
16Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State Welding
and Processing Technology
Solid State Welding
Overview of Main Processes
17Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesHigh-Frequency Welding (1/2)
4
18Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesHigh-Frequency Welding (2/2)
Sample of Frequency Ranges:
100kHz - 800kHz
19Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesFlash Welding (1/1)
20Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesStud Welding (1/1)
21Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesCold Pressure Welding (1/3)
22Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesCold Pressure Welding (2/3)
Aluminium - Copper
23Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesCold Pressure Welding (3/3)
Variant: Off-set Flash
5
24Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesDiffusion Welding (1/3)
25Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Autoclave (Oven)
Overview of Solid State ProcessesDiffusion Welding (2/3)
26Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesDiffusion Welding (3/3)
27Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Interfaces in Ultrasonic Welding
Overview of Solid State ProcessesUltrasonic Welding (2/9)
28Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesUltrasonic Welding (3/9)
29Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Question:
What is happening at
contacting interfaces?
Overview of Solid State ProcessesUltrasonic Welding (4/9)
6
30Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Hysteresis Cycle
(elastic domain)
Overview of Solid State ProcessesUltrasonic Welding (5/9)
Sample of Frequency Ranges:
10kHz - 75kHz
31Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
time
Compacting Anchor Welding Excess
Overview of Solid State ProcessesUltrasonic Welding (6/9)
Sequence of stages during the transient cycle of USW
32Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesUltrasonic Welding (8/9)
Old concept equipments
33Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesUltrasonic Welding (9/9)
Application samples in metals
34Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesExplosion Welding (1/5)
35Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesExplosion Welding (2/5)
7
36Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesExplosion Welding (3/5)
37Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesExplosion Welding (4/5)
38Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State Welding
and Processing Technology
Friction Based Technology
“Third-Body” Region
39Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
“Third-Body” Region
Based Technology
40Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Based TechnologySample of Processes
Friction Extrusion Friction Hydro Pillar
T
WI, E
ng
lan
d
41Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based InnovationsFriction Riveting at HZG
Courtesy of
8
42Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesFriction Welding (1/13)
Joint design possible solutions
43Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Based TechnologySample of Processes
Friction Welding
Internacional Patent
2/1956 (A.I.Chudikov)
44Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
As welded Tensille test Bending test
Overview of Solid State ProcessesFriction Welding (9/13)
Application samples: Inertia Wheel transmission of CuOFHC / AA4043
45Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesFriction Welding (10/13)
Application samples: Long drilling shafts for in-land prospection
46Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesFriction Welding (11/13)
Inertia wheel transmission application to produce “transmission shafts”
47Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Before...
...After
Overview of Solid State ProcessesFriction Welding (12/13)
Application samples: Manufacture of prostheses
9
48Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of Solid State ProcessesFriction Welding (13/13)
Application samples: Automotive industry
49Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based TechnologyFriction Surfacing: Fundaments
50Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based TechnologyFriction Surfacing: Secondary Flash Formation
Stainless steel rod (AISI 316) over High strength
steel plate (Optim 700 MC Plus)
51Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based TechnologyFriction Surfacing: Secondary Flash Formation
52Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State Welding
and Processing Technology
Friction Stir Welding
Fundaments
53Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of FSW FeaturesFSW Licenses Issued by TWI
Cumulative number of licences issued by TWI with time:
10
54Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of FSW FeaturesFundaments and Parameters
Representation of parameters of FSW
55Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding ProcessFundaments – Heat Input
56Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding ProcessFundaments – Clamping System
Advanced Automatized Solutions
Conventional Solutions
Vacuum
Hydraulic
Magnetic
57Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding ProcessFundaments – Joint Design
58Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding ProcessFundaments – (…more) T-Joint Designs
59Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding ProcessFundaments – Example of Joints
SPIF of tailored blanks welded by FSW
11
60Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding ProcessFSW @ Aalto University: Tool Development
Original case study was aluminium fuel tank
• AA5754-H22, 3 mm thick
• Conventional methods versus FSW
After 3 concepts the solution is capable to:
• To produce extruded-like hollow rectangular
structures in AA5XXX series aluminium
• heat input, low distortion, high quality welds
with high strength
• Variable: lenght, width, height and repeatable
Materials Joining and NDTDepartment of Engineering Design
and Production
Friction Stir Welding ProcessApplicability to Engineering Metals
Al Alloys(heat treatable and non heat treatable)
Cu and Cu Alloys
Steel
Mg Alloys
Ti AlloysNi (based) Alloys
62Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of FSW FeaturesBasic Features
Typical transversal macrostructure of a FSW butt joint:
63Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of FSW FeaturesMetallurgical Characterization
AA5083-H111(4.0 mm)
Interface TMAZ/Nugget in transversal macrostructure of a FSW butt joint:
64Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of FSW FeaturesTool Features: Heart of the FSW Process
Retracted-Pin Tool (NASA)
65Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding ProcessFundaments – Tool Architecture
Compact tool
Bobbin-toolFixed/Self-adapting Gap
Modular tool
12
66Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding ProcessFundaments – Tool Architecture
…for thermoplasticswith/without pre-heat
Stationary Shoulder
Courtesy / Source: TWI
Stationary Shoulder
…for engineering metals
67Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding ProcessFundaments – Tool Architecture
FSW Tool - Assisted by Joule Effect
68Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Overview of FSW FeaturesTools for FSW of HTM: Steel, Titanium, Nickel Based Alloys
Tool Material
(Hybrid WRe:PCBN):
Q60 composite tool consisting of
60% PCBN + 40% W-Re alloy
Shank: tungsten carbide
69Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Modelling of Friction Stir WeldingComplex Multiphysics Coupled Phenomena
Materials Joining and NDTDepartment of Engineering Design
and Production
Friction Stir Welding ProcessFundaments – Advantages versus Disadvantages
Welds materials whose structure and properties would be degraded by fusion welding
Minimal distortion + Low residual stress levels compared to fusion welding processes
Environmentally friendly + Safe: No fumes + No radiation + High energy efficiency
Easy repeatability + Good control: Suitable for automation and robotization
Good mechanical properties: No cracks + No porosity
No consumables (…shielding gas may support the BM and tool for higher temperatures)
Joint can be produced from one side and in all positions
Minimal edge preparation required
Not influenced by magnetic forces
Backing anvil required (except bobbin stir tools)
Keyhole at the end of each weld (except when a tool with a retractable probe is used)
Workpiece requires rigid clamping (except when the Twin-stir™ variant is used)
Application not as flexible as certain fusion welding processes
71Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
FSW Joint Design FeaturesStandards
13
72Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Materials Joining and NDTFSW @ Aalto University
ESAB LEGIOTM
FSW 5UT
Z-axis Control: Position + Speed + Force
Maximum Forces: Fz_max = 100kN (Fx_max = Fy_max = 40kN)
Maximum Welding Travel Speed: Vx_max = Vy_max = 4m/min
Maximum Spindle Power = 30kW ; Maximum Spindle Speed: max = 3000rpm
Work Envelope (x ; y ; z) : 2000mm x 400mm x 300mm
Special focus on the application to: Al, Cu, HSSteels, SSteels, and Ni based alloys
73Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State Welding
and Processing Technology
Friction Stir Welding
Industrial Application Samples
74Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
1st know industrial application (~1995) ...
Production of panels from extruded closed profiles for deep-frozen fishing
vessels
Note:
FSW is performed
from both sides of the
butt joint
Industrial ApplicationNaval Industry – Sapa@Sweden
75Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationAeronautic Industry – Eclipse Aviation@USA (1/4)
76Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationAeronautic Industry – Eclipse Aviation@USA (4/4)
Fuselage
77Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Vertical and orbital FSW joints: 1998-
2000
An FSW facility dedicated for the production of the
fuel tanks of Delta IV
Industrial ApplicationAerospace Industry – Boeing Co.@USA (2/4)
14
78Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationAerospace Industry – Boeing Co.@USA (3/4)
New FSW for Space Launch System:
Vertical Assembly Center (VAC)
(NASA’s Michoud Assembly Facility New Orleans)
61 m Tall x 8.4 m Diameter cryogenic liquid hydrogen and liquid oxygen that will feed the vehicle’s RS-25 engine
79Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationAutomotive Industry
80Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
The special characteristics of the friction stir welded joint enable the forming of the final part
without problem: Ecodal-608 PX sheet (pre-aged T4 temper) .
Dissimilar in Thickness Tailored Blank =1.7 mm + 2.4 mm
Industrial ApplicationAutomotive Industry – AUDI R8 Le Mans (2/2)
81Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationAutomotive Industry
82Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationAutomotive Industry – Sapa, Sweden
A car features
countless
application areas
for aluminium, as
can be seen
in this picture
taken at the
Aluminium 2002
Fair in Germany,
at the SAPA
stand
83Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solution: Replacement of current metals with lighter alloys
Magnesium is a very light alloy (ρ = 1750 kg/m3)
Has a good castability allowing the casting of complex shapes
Challenge
Current joining methods present several difficulties
Critical corrosion susceptibility
FSW is a good method for similar and dissimilar joints with Mg alloys
M.K.Kulekci, “Magnesium and its alloys applications in automotive industry,” Int.J.Adv.Manuf.Technol., 39, 851–865, 2007.
Industrial ApplicationMg Alloy for Automotive Industry
15
84Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Automatized system for FSW of
electric engine housing
Industrial ApplicationHousing – Hydro Aluminium Profile, Norway
85Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationHousing - Bang & Olufsen, Germany
86Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationArchitecture Application – Nobel Peace Centre, Oslo Norway
87Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationSwedish Nuclear Fuel and Waste Management Co (SKB) (1/3)
Final repository for the waste and a
reliable way of encapsulating and sealing
the copper canisters of spent nuclear
fuel, which must remain intact for some
100 000 years. Copper canisters (~ 5 m
long) for spent nuclear waste are
cylindrical, featuring a near 50mm-thick
copper corrosion barrier and a cast iron
insert for mechanical strength. The
canister, with an outer diameter of 105
cm, must be sealed using a welding
method that ensures extremely high joint
quality and integrity.
88Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationShipbuilding Industry – Steel (source: HILDA project)
FSW… Aims to avoid This!
Courtesy / Source: TWI
89Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationApple iMAC 2012 (2/2)
16
90Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationElectrical Transformers Bobbin's - SIEMENS, Portugal (1/2)
91Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Industrial ApplicationElectrical Transformers Bobbin's - SIEMENS, Portugal (2/2)
92Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State Welding
and Processing Technology
FSW Based Innovations
FSW Variants
93Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding
Based InnovationsBobbin-Tool Stationary-Shoulder
94Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding
Based InnovationsRas-Stir Skew-Stir Com-Stir
95Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Welding
Based InnovationsRe-Stir Dual-Rotation Twin-Stir
17
96Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Solid State Welding
and Processing Technology
FSW Based Innovations
Friction Stir Based Techniques
97Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based InnovationsFriction Stir Processing
FS Processing apply the principles of FSW to develop materials microstructures and improving superficial and in-volume properties
Cleaning and preparation of surface without special care
Used in different positions with no need of high levels of energy consumed
It is very successful in the modification of various properties such as formability,
hardness, yield strength, fatigue and corrosion resistance
It is also becoming very effective in the production of MMC and for the
production of materials with superplastic behaviour
98Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based InnovationsFriction Stir Processing
Embedding of
SiC particles for FGM
Overlap Ratio OR
Results for:
FS Processing in-Volume
Smooth concave shoulder for better
superficial appearance
99Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based InnovationsFriction Stir Channelling
FSC is an innovative process within solid-phase manufacturing technologies able to produce, in a single operation, continuous internal (closed) channels in monolithic plates
FSC is a disruptive innovation enabling higher efficiency in energetic applications and advances of structural design of products
Channels can have any path and many different shapes and locations
100Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based InnovationsFriction Stir Channelling: Potential Applications
Conformal Cooling of Mould Cavity
101Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based InnovationsFriction Stir Microforming
Friction stir microforming (FSM) is an integration of friction stir technology
with superplastic materials science, to microform metallic parts
Friction stir microforming of superplastic aluminum alloys Al-7075 and Al-4Mg-1Zr [Mishra]
Microdie used for forming the microparts consists of two rectangular 1mm long microEDM
channels, 100 and 200 mm wide, and 500 mm in depth
Applications:
• Micro-electromechanical systems (MEMS) + Microsystem technologies (MST)
18
102Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based InnovationsSelf Embossing and In-Process Forge/Forming
Impressed marks can be produced during the FSW operation and came
from inverse engraving in the anvil support plate
Self embossing - showing impressed marks produced during
the FSW operation [Courtesy of TWI]
Embossed FSW weldEngraved anvil
103Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based InnovationsFriction Stir Spot Welding
104Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based InnovationsFriction Spot Welding
105Engineering Materials
Materials Joining and NDTDepartment of Mechanical Engineering
Friction Stir Based InnovationsNear-Net Shaped Manufacture
6 mm X 6 mm thick AA5083