generalities and activities at institut de soudure...generalities weldable materials : – aluminium...
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FSW Generalities and activities at Institut de Soudure
Amarilys BEN ATTAR
Generalities
Friction Stir Welding (FSW) was
developed by TWI
First patent in 1991
Principles:
– A rotated cylindrical-shouldered tool with
a profiled probe is plunged between two
clamped parts
– Heat is generated by friction leading to
the softening of the parent material(s)
– Tool displacement along the weld line
results in the formation of a solid state
joint without filler metal
– Metallic bounding is achieved by
recrystallization
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Generalities
Welding tool :
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SHOULDER PIN
Elements Purpose Contact
PIN
Stir workpiece’s materials Create plastic deformation owing to
rotation and translation movements Material extrusion
In the joint
SHOULDER
Maintain stirred material around the pin Generate additional heat to obtain
localized workpieces softening
Material forging
On the workpieces top
surface
Generalities
Process phases :
– Plunging phase:
– Welding phase:
• The tool moves along the joint
• The joint is formed behind the tool with the base metal (no filler metal)
– Pulling out phase:
• The final phase is to pull out the welding tool from
the weld seam
• Depending on tool design, an exit hole may be left when the tool has been withdrawn
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The pin plunges in
workpieces Tool put
into
rotation
Contact between
shoulder and top
surfaces of workpieces Welding
Generalities
Welding parameters :
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The main process parameters:
Tool rotation speed: N [rpm]
Welding speed: V [mm/min]
Welding force: F [kN]
Other parameters:
Tool shape and material
Fixture system
Welding machine
Generalities
Appearance
Transverse cross section
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Tool foot print
Joint
Welding direction
Flash
Stir
zone
TMAZ
HAZ HAZ
PM PM
Joint center line (butt joint configuration)
Stir zone
TMAZ: Thermo-Mechanically Affected Zone
HAZ: Heat Affected Zone
BM: Base Material
Generalities
Weldable materials :
– Aluminium alloys: 2xxx, 5xxx, 6xxx and 7xxx series
– Copper and Magnesium alloys
– Multi-material joining: Aluminium/Copper, Aluminium/Steel,
– Steel or Titanium Alloys under specific conditions
Joint configurations:
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1. Square butt
2. Combined butt and lap
3. Single lap
4. Multiple lap
5. 3 pieces T butt
6. 2 pieces T butt
7. Edge butt
8. Possible corner fillet weld
9. Lap fillet
Picture Technique de l’Ingénieur
1 2 3
4 5 6
7 8 9
Generalities
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Weld characteristics Implementation
Weldability of all aluminium alloys (2*** and 7*** series)
Mechanical characteristics (fatigue
resistance)
Ability to weld dissimilar material
No filler metal
No consumable
Low distortion
Repeatable and easily automatizable
“clean” process
Gap management
Difficulties to weld Steel or Titanium Alloys (welding tool life time)
Fixture to maintain the part during welding : implementation, costs
Welding configurations (welding head and fixture)
Invest costs
FSW Center
FSW at Institut de Soudure
– FSW center established in 2004
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– Achievements:
• Industrials developments of FSW:
o Feasibility and development,
o Demonstrator,
o Process industrialization.
• Research: participation in major research projects in FSW with university and industrial partners
FSW Center
Equipment:
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Institut de Soudure
Gantry machine
3 tool technologies
Maximum force: 89 kN
Maximum welding speed:
2 m/min
Maximum rotational speed:
2 000 RPM
3D capability
(5 axis)
Working volume:
X 19 m
Y 3 m
Z 1.2 m
Roll ±35°
Tilt ±15°
FSW Center
Equipement:
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Institut de Soudure
Robot
Conventionnal tool technology
Laser seam tracking
Maximum force: 15 kN
Maximum welding speed: 6 m/min
Maximum rotational speed:
2 500 RPM
3D capability (6 axis)
Working volume: X 2.5 m
Y 2.5 m
Examples of prototypes achievement at IS
Robot developments: Robotized FSW for helicopter parts–Institut de Soudure
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Examples of prototypes achievement at IS
Robot developments:
Butt joint
configuration
complex trajectory.
Dissimilar assembly (2xxx
series with 7xxx), butt joint
configuration 2 mm
thickness, complex
trajectory
Welded part (Robotic FSW) –Institut de Soudure
Robotic FSW–Institut de Soudure
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Examples of prototypes achievement at IS
Gantry machine developments:
– Dissimilar assembly: cast and wrought aluminium alloys
• Butt joint configuration AlSi13 / AlSi7Mg0.6
• Use of retractable pin tool technology to avoid the hole at the end of the weld.
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Examples of prototypes achievement at IS
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Gantry machine developments:
– Welding of aluminium profile for longer lengths
– Railway application
Examples of prototypes achievement at IS
Gantry mahcine developments
– WEL AIR European Project
– PIAGGIO P180 AVANTI demonstrator:
• Objective: 40 000 cycles, i.e. 4 times the rated plane service life.
• 120 000 cycles reached, i.e. 12 times the rated plane service life without fatigue damage
Fatigue test
Friction stir welding of demonstrators
Friction stir welding of a stiffener
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Examples of prototypes achievement at IS
Gantry machine developments:
– Friction stir welding of a propellant tank demonstrator
• R&T program to prepare ARIANE 6
• Replacement of TIG welding to reduce tank thickness
– Application :
• 4 longitudinal and 1 circumferential weld
• Aluminium Lithium alloy in butt joint configuration, 5 mm thickness
Manufactured panels – Airbus Defence & Space
Equipment setting at the Institut de Soudure
Longitudinal welding - Institut de Soudure
Circumferential welding - Institut de Soudure Welded prototype -
Institut de Soudure
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Examples of prototypes achievement at IS
Gantry machine development:
– OFFSET project : Optimized Front Fuselage Structure with Enhanced
Technologies
– Welding of 7 stiffeners on an upper cap skin
• 7175 T7351 and 2024 T42
• Lap joint (homogeneous)
• Lap fillet joint (heterogeneous
Upper cap welding - Institut de Soudure
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Upper cap skin after welding and testing
Prototype UT testing carry on by Institut de Soudure
Aeronautic application
ECLIPSE 500 (Eclipse Aviation)
– Jet 6 seats – june 2006
– Welding of stringers on the panel Remove of 7300 rivets (60%)
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Eclipse 500
Friction stir welds
Power-train - electric
– Aluminium/copper connector for
various applications in electrical
infrastructure and batteries
– Material is welded as flat blanks and
subsequently machined to the specific
geometry
– High electrical conductivity fulfilled
Power train - cooler
– Water cooled components for
electrical controller in hybrid or electric
vehicles
– Water tight welds sealing the water
cooling channels
– Material: mostly high pressure die cast,
sometimes in combination with sheet
material as cover for tooling circuits
Renault ZOE battery
Al/copper connector friction stir welded
Automotive applications
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Mazda RX-8
– Spot welding
Audi R8
– Worldwide first friction stir tailored welded blank in the
automotive serial production
– Left and right sides of the center tunnel (crash relevant structure)
– Blanks are welded in the flat condition prior to the stamping
operation
Automotive applications
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Automotive applications
Wheel : Saint-Jean industrie application
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Mercedes SL :
– Tailored welded blank as center tunnel
reinforcement (crash relevant structural
component) • Blank is made from three sheets and welded in the flat
condition prior to the stamping operation
• TWB allows engineered stiffness of the center area in
combination of weight saving and reduction in number
of parts
• No rework after welding required neither for stamping,
nor for assembly or painting
– Floor structure made from three thin-walled
hollow extrusions • crash relevant structural component
• Reduced weld distortion enables high dimensional
accuracy
Automotive applications
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Automotive applications
Chassis assembly : HONDA application
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Tank assembly:
Spatial implementation
Boeing
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Tank assembly:
Spatial implementation
Lockheed Martin
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Contacts:
Sales:
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Bruno KAICI
Sales Mananger
Mobile : +33 (0)6 47 12 77 25
Amarilys BEN ATTAR
Center Manager – FSW specialist
Joining platform – Research Expertise Division
Tel : +33 (0)6 86 66 56 02
Institut de Soudure – Centre Brasage –Soudage diffusion - FSW
Zone d’activités Aéroport de Metz
2-4 rue Pilâtre de Rozier
57420 Goin
France
www.isgroupe.com
www.essa-eaps.isgroupe.com
Technical: