This is an electronic reprint of the original article.This reprint may differ from the original in pagination and typographic detail.
Powered by TCPDF (www.tcpdf.org)
This material is protected by copyright and other intellectual property rights, and duplication or sale of all or part of any of the repository collections is not permitted, except that material may be duplicated by you for your research use or educational purposes in electronic or print form. You must obtain permission for any other use. Electronic or print copies may not be offered, whether for sale or otherwise to anyone who is not an authorised user.
Santos Vilaca da Silva, PedroFriction Stir Welding and its Variants Applied to Metals
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 and its Variants Applied to Metals. Paper presented atHitsaus ja muut liittämismenetelmät, Tampere, Finland.
1
Professor Pedro Vilaça *
4th December 2014 Tampere, Finland
Friction Stir Welding and its Variants Applied to Metals
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
2
Materials Joining and NDT Department of Engineering Design
and Production
Friction Based Technology Sample of Processes
Friction Welding Friction Linear Welding
Materials Joining and NDT Department of Engineering Design
and Production
Friction Based Technology Sample of Processes
Friction Extrusion Friction Hydro Pillar Friction Riveting
3
Materials Joining and NDT Department of Engineering Design
and Production
Friction Based Technology Sample of Processes
FS Production of
Functionally Graded Materials (FGM)
FS for Built-Up
Friction Surfacing
Materials Joining and NDT Department of Engineering Design
and Production
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
4
Materials Joining and NDT Department of Engineering Design
and Production
Friction Stir Welding Process Fundaments and Parameters
Materials Joining and NDT Department of Engineering Design
and Production
Friction Stir Welding Process Fundaments – Joint Design
5
Materials Joining and NDT Department of Engineering Design
and Production
Friction Stir Welding Process Fundaments – Example of Joints
SPIF of tailored blanks welded by FSW
Materials Joining and NDT Department of Engineering Design
and Production
Friction Stir Welding Process Fundaments – Clamping System
Advanced Automatized Solutions
Conventional Solutions
Vacuum
Hydraulic
Magnetic
6
Materials Joining and NDT Department of Engineering Design
and Production
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
Materials Joining and NDT Department of Engineering Design
and Production
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
7
Materials Joining and NDT Department of Engineering Design
and Production
Friction Stir Welding Process Applicability to Engineering Metals
Al Alloys (heat treatable and non heat treatable)
Cu and Cu Alloys
Steel
Mg Alloys
Ti Alloys Ni (based) Alloys
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys Shipbuilding Industry
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 %
8
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys Aeronautic Industry
Eclipse Aviation @ USA
Wing
Fuselage
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys Aeronautic Industry
Courtesy/Source: TWI
9
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys Aeronautic Industry – Data for AA2024-T351 (t=4 mm)
(R=0
)
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys Aeronautic Material – Data for AA2024-T3 (Tailor-Welded Blank)
Residual deformation field: Legend: 0.5 mm between lines
10
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys 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
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys Automotive Industry
Center Tunnel for
AUDI R8 Le Mans
Courtesy/Source: TWI
Courtesy/Source: HZG
11
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys Automotive Industry
Aluminium 2002 Fair in Germany
@ SAPA stand
Courtesy/Source: TWI
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys Railway Industry
A-Train concept from
Hitachi, Ltd @ Japan for
rolling stock based on FSW
12
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys Railway Industry
UFF/Cullen Audit Report by Ladbroke Grove Inquiry recommended the
application of FSW replacing MIG
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Al Alloys Informatics Industry
Apple 21.5 and 27-inch iMACs 2012 @ USA
13
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application Al Alloys Electrical Industry
Electrical Transformers Bobbin's – SIEMENS @ Portugal
Materials Joining and NDT Department of Engineering Design
and Production
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 Application to Mg Alloy Automotive Industry
14
Materials Joining and NDT Department of Engineering Design
and Production
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
Industrial Application to Mg Alloy Automotive Industry
Plates: AZ31 (thickness = 2 mm)
Materials Joining and NDT Department of Engineering Design
and Production
HAZ … to MB Nugget
A Weld Root (no LOP)
B Nugget
B A
Shoulder
Industrial Application to Mg Alloy Automotive Industry - Corrosion Resistance Analysis
15
Materials Joining and NDT Department of Engineering Design
and Production
Sample MB Travel speed [mm/min]
100 200 400
[wt. %]
Corroded 3.10 9.26 5.77 3.69
Corrosion Testing Experimental Procedure
Saline Environment - ASTM B117:95 - (5%NaCl) until 350h period or until extreme corrosion that damaged the part was encountered
FS
W R
oot
FS
W F
ace
B
M
Industrial Application to Mg Alloy Automotive Industry - Corrosion Resistance Analysis
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Steel Shipbuilding Industry
Aalto U belongs to Advisory Group of HILDA project:
16
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Steel Shipbuilding Industry (source: HILDA project)
FSW… Aims to avoid This!
Courtesy / Source: TWI
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Steel Shipbuilding Industry (source: HILDA project)
FSW Tool: a major challenge ! …Materials and Life Assessment
Courtesy / Source: TWI
17
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Steel Shipbuilding Industry (source: HILDA project)
FSWelding and FSProcessing:
Courtesy / Source: TWI
Materials Joining and NDT Department of Engineering Design
and Production
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. The
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.
Industrial Application to Cu Nuclear Fuel and Waste Management (Posiva + SKB)
18
Materials Joining and NDT Department of Engineering Design
and Production
Industrial Application to Cu Nuclear Fuel and Waste Management (Posiva + SKB)
Materials Joining and NDT Department of Engineering Design
and Production
Friction Stir Welding
Based Innovations
19
Materials Joining and NDT Department of Engineering Design
and Production
Friction Stir
Based Innovations
4th December 2014 Tampere, Finland
Thank You / Kiitos / Tack
Department of Engineering
Design and Production