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Santos Vilaca da Silva, PedroFriction Stir Welding – New Possibilities for Designers

Published: 01/01/2014

Document VersionEarly version, also known as pre-print

Please cite the original version:Santos Vilaca da Silva, P. (2014). Friction Stir Welding – New Possibilities for Designers. Paper presented atNordic Welding Conference, Tampere, Finland.

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Professor Pedro Vilaça *

5-6th November 2014 Tampere, Finland

Friction Stir Welding New Possibilities for Designers

Associate Professor

Materials Joining and NDT

Department of Engineering

Design and Production

* Contacts Address: P.O. Box 14200, FI-00076 Aalto, Finland Visiting address: Puumiehenkuja 3, Espoo [email protected] ; Skype: fsweldone

Materials Joining and NDT Department of Engineering Design

and Production

“Third-Body” Region

Based Technologies

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Friction Stir Welding Process Inventor: Wayne Morris Thomas @ TWI (UK)

1. Thomas W M, Nicholas E D, Needham J C, Murch M G, Temple-Smith

P, and Dawes C J, ‘Improvements relating to friction stir welding’.

US Patent No. 5,460,317, 1991

2. Nicholas E D and Thomas W M: ‘Improvements Relating to Friction

welding’. International Patent Application, B23K 20/12, b29C

65/06, May 30th 1995

The responsible for the most significant development of welding technology

in recent history

Last Patent (US 5,813592) assigned to TWI Expires: 29 September 2015


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Friction Stir Welding Process Fundaments and Parameters

FSW was patented by TWI, 1991, W. Thomas et al., UK

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Friction Stir Welding Process Fundaments – Microstructure Features

AA5083-H111 (4.0 mm)

AA2024-T3 (4.8 mm)

Longitudinal – FSW it´s 3D ! Transversal and…


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Friction Stir Welding Process Fundaments – Hot versus Cold Material Flow Pattern

Vickers Hardness Field

Vickers Hardness Field

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Friction Stir Welding Process Fundaments - Typical HV02 Profile for Al alloys


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Friction Stir Welding Process Fundaments – Tool Geometry

Probes

Shoulders

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Friction Stir Welding Process Fundaments – Tool Architecture

Compact tool

Bobbin-tool Fixed/Self-adapting Gap

Modular tool


and Production


…for thermoplastics with/without pre-heat

Stationary Shoulder

Courtesy / Source: TWI

…for engineering metals

FSW_bead.wmv

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FSW Tool - Assisted by Joule Effect


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Friction Stir Welding Process Fundaments – Joint Design

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Friction Stir Welding Process Fundaments – (…more) T-Joint Designs


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Friction Stir Welding Process Fundaments – Example of Joints

SPIF of tailored blanks welded by FSW

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Friction Stir Welding Process FSW @ 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


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Friction Stir Welding Process Fundaments – Heat Input

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Friction Stir Welding Process Fundaments – Clamping System

Advanced Automatized Solutions

Conventional Solutions

Vacuum

Hydraulic

Magnetic


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Materials Joining and NDT FSW @ 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

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Friction Stir Welding Process Fundaments – Example of Materials


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Friction Stir Welding Process Fundaments – Standards

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Friction Stir Welding Process Fundaments – 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


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Industrial Application Samples of FSW Shipbuilding Industry – Al Alloys

First vessel (catamaran) in history made from

FSW panels was built by Fjellstrand AS in 1996

The panels were made by Marine Aluminium.

This was what actually kick-started the

industrialization of FSW process

First known-application (1995):

• Production of panels from

extruded closed profiles for

deep-frozen fishing vessels

Catamaran where 25 % were pre-manufactured

with FSW reducing costs by 4 to 5 %

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Constant Parameters:

AA5083-H111 (4mm)

FSW@rolling direction

=1120rpm

Fatigue Tests


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Industrial Application Samples of FSW Shipbuilding Industry– Al Alloys

Intergranular Corrosion Tests ASTM G67: Nitric Acid @30ºC 24h

AA5083-H111 (4mm)


=1120rpm

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Exfoliation Corrosion Tests ASTM G66: Complex Solution @65±1ºC 24h

AA5083-H111 (4mm)


=1120rpm


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Industrial Application Samples of FSW Shipbuilding Industry – Steel

Aalto U belongs to Advisory Group of HILDA project:

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Industrial Application Samples of FSW Shipbuilding Industry – Steel (source: HILDA project)

FSW… Aims to avoid This!



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Industrial Application Samples of FSW Shipbuilding Industry – Steel (source: HILDA project)

FSWelding and Processing:


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Industrial Application Samples of FSW Aeronautic Industry

Eclipse Aviation @ USA

Wing

Fuselage


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Industrial Application Samples of FSW Aeronautic Industry – Data for AA2024-T351 (t=4 mm)

(R=0

)

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Industrial Application Samples of FSW Aeronautic Material – Data for AA2024-T3 (Tailor-Blanks)

Residual deformation field: Legend: 0.5 mm between lines


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Industrial Application Samples of FSW Aerospace Industry

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

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Industrial Application Samples of FSW Automotive Industry

Aluminium 2002 Fair in Germany

@ SAPA stand

Courtesy/Source: TWI


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Industrial Application Samples of FSW Automotive Industry

Weight savings can go from 20% up to 60% by replacing steel metallic structure

of Automotive Seats by Mg alloys while complying with automotive regulations

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Industrial Application Samples of FSW Railway Industry

A-Train concept from

Hitachi, Ltd @ Japan for

rolling stock based on FSW


and Production


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UFF/Cullen Audit Report by Ladbroke Grove Inquiry recommended the

application of FSW replacing MIG


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Industrial Application Samples of FSW Informatics Industry

Apple 21.5 and 27-inch iMACs 2012 @ USA

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Industrial Application Samples of FSW Electrical Industry

Electrical Transformers Bobbin's – SIEMENS @ Portugal


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Friction Stir Welding

Based Innovations

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Friction Stir

Based Innovations


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Industrialization of FSW …Demands Reliable Quality Assessment

- However the actual NDT reliability in characterizing and sizing the typical FSW defects still remains a challenge.

- Thus the development of reliable NDT techniques is fundamental.

- The transference of FSW to high quality demanding industries depends on the level of reliability of the weld joins.

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Friction Stir Welding Possible Defects: e.g. Butt Joints


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Friction Stir Welding Defects: Size, Location, Morphology

Production and characterization of the typical defects of FSW

AA2024-T351

(3.8 mm)

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Friction Stir Welding Effect of Defects


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The most significant defects are the roots ones. Thus, root defects are the target defects on the NDT Techniques.

Friction Stir Welding Effect of Defects

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NDT Dedicated for FSW IOnic Probe Results

The results clearly show a signal disturbance which is proportional to the size of the defects


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NDT Dedicated for FSW Defect Index

The application of the Defect Index to the 3 defects types clearly show a proportionality between then. This result is confirmed by different frequencies.

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NDT Dedicated for FSW New features of IOnic Probe

Production of Ionic Probe on flexible subtracts, i.e.: Kapton®

Allow NDT Inspection of curved surfaces

29th October 2014 Turku, Finland

Thank You / Kiitos / Tack

Department of Engineering

Design and Production

santos vilaca da silva, pedro friction stir welding – new ... · the panels were made by marine...

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