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Copyright © TWI Ltd 2015
Bertrand Flipo Friction and Forge Processes
Linear Friction Welding Technology Update
Copyright © TWI Ltd 2015
Understand, explore, demonstrate the LFW process,
For the benefit of the wider community,
For industrial implementation,
And widespread use.
LFW technology update
Copyright © TWI Ltd 2015
17 Engineers and Technicians
Based in Cambridge
53 years of R&D in Friction Processes One of the first in Friction Welding
Pioneered Linear Friction Welding
Invented Friction Stir Welding
Friction and Forge Processes team
Copyright © TWI Ltd 2015
LFW
Understand
Explore
Demonstrate
Transfer
Implement
Qualify
Friction and Forge Processes activities
Copyright © TWI Ltd 2015
LFW
Understand
Explore
Demonstrate
Transfer
Implement
Qualify
Friction and Forge Processes activities
Copyright © TWI Ltd 2015
Anthony McAndrew - Presenting Contaminant Removal in Ti6Al4V
1st publication: 2013
2nd publication: 2014
Thesis: 2015
Lucie Lee Novel Industrial Applications
1st publication: 2016
2nd publication: 2017
Thesis: 2018
Modelling of LFW
Copyright © TWI Ltd 2015
Interpretation of LFW cycles
Making sense of LFW data
Correlation with HS video
Better, automated reports
Displaying relevant information
Weld record
Process analysis
Finding new ways to display difficult to grasp information
Analysis of LFW cycles: previous work
Copyright © TWI Ltd 2015
Analysis of LFW cycles: current work
TiFab – presenting
Independent monitoring of LFW cycles Helps the LFW Process Engineer in making his/her
decision
Offer evidence to support the welding operation Unobtrusive addition of sensors High sampling rate
Open, adaptable tools
Individual weld cycles (QC) Series repeatability
Project should be transferable to
other machines in the future
Copyright © TWI Ltd 2015
LFW
Understand
Explore
Demonstrate
Transfer
Implement
Qualify
Friction and Forge Processes activities
Copyright © TWI Ltd 2015
Demonstrating capabilities of LFW
Core Exploration
•Joint formation mechanisms
•New materials
•Dissimilar joints
Like for like performance
•Parent metal conditioning
•Welding parameters
•Post weld heat treatments
Smart manufacture
•New parts
•Design for LFW
•Legacy components
New design freedoms
• Material tailoring
• Nested performance
Copyright © TWI Ltd 2015
Demonstration of ring manufacture Formed ring
Keystone weld
Recent industrial interest Life extension programmes
Loss of original mean of manufacture
LFW can step in to offer cost controlled replacement parts Life extension programs
of a different order of financial magnitude
Previous efforts: Legacy components
Copyright © TWI Ltd 2015
Medium to large size M16 to M60
Corrosion resistant: Ni superalloy
Made on request: Milled from solid Forged from billet
Long lead times and expensive: 4 -6 month order time Circa $200K for a bolt set
(40 bolts)
CRP2014: Bolts for sub-sea oil & gas
Copyright © TWI Ltd 2015
Welding of conditioned material
Target: API 6A718 specification
IN718: small process window
PWHT bringing back material properties to API 6A718
CRP2014: Bolts for sub-sea oil & gas
As welded After post weld heat treatment PWHT tensile
Demonstrator part
Copyright © TWI Ltd 2015
Airware 2050: latest generation Al-Cu-Li alloy for plates
Assessment of parametric conditions and joint performance: over 100 welds
“Some of the best aluminium welds ever observed”
LFW route for Airware parts
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Selected parametric conditions
Rp0.2 UTS A%
Copyright © TWI Ltd 2015
Latest generation Al-Cu-Li alloys
New Al MMCs (Al-Al2O3)
Advanced Ti MMCs (TiSiC)
Composites (GFRP, CFRP)
Combinations of the above
CRP2017: Advanced lightweight materials
Courtesy of Tisics
Copyright © TWI Ltd 2015
Smart manufacture
Copyright © TWI Ltd 2015
Monolithic, large structures Go beyond large forging sizes Maintain throughput capability Part count reduction Knock on benefits in maintenance
Nested performance Combine LFW with other high-end
processes for component performance
Material tailoring Strategic placement of dissimilar
alloys Embed features Enable use of smart materials Further costs control
LFW: New design freedoms
Ti6246
Ti64
Potential Example:
Courtesy of Airbus
Copyright © TWI Ltd 2015
LFW
Understand
Explore
Demonstrate
Transfer
Implement
Qualify
Friction and Forge Processes activities
Copyright © TWI Ltd 2015
Aerospace events
Introduce: badly known process
Inform
Update
Training Courses
IWE courses
On-demand Process training
Sponsored projects
Government / EU
Industry
LFW Technology Transfer
Copyright © TWI Ltd 2015
The leading LFW event in the World
Growing interest
TWI’s Biennial Int’l LFW Symposium
Contact: [email protected]
2015
2013
2011
Copyright © TWI Ltd 2015
Description\ Route Units CNC LFW Description\ Route Units CNC yearly LFW yearly Component
OPERATIONAL COSTS Volume of finished part cm3 163.00
Working weeks per year week 50 50 Yearly rate of production unit 20,000
Weekly working hours h/week 120 120
Yearly production hours h/year 6,000 6,000 CNC MANUFACTURING ROUTE material volume cm3 2179.00
Yearly rate of production unit 20,000 20,000 Buy to fly ratio BtF 13.4
Production batch size unit 10 10 Volume of scrap material cm3 2,016
Production life year 20 20 Weight of scrap material kg 9
Purchase price per machine £ 400,000 1,400,000 Estimated material purchase per part £ 338
Machine economic life year 5 20 Estimated scrap value per part £ 14
Yearly interest rate % 1.5 1.5 Estimated material cost per part £ 324
Depreciation rate (over economic life) % 90 90 Roughing cut volume cm3 2,008
Nominal power kWh 15 85 Roughing cut time min 205
Electricity rate £/kWh 0.13 0.13 Roughing tool cost £ 287
Workshop floor occupation m2 50 100 Roughing cost £ 556
Monthly workshop rental rate £/m2 30 30 Finishing cut volume cm
3 8
Labour cost £/h 60 60 Finishing cut time min 7
Yearly maintenance cost £ 5,000 25,000 Finishing tool cost £ 31
Yearly energy usage cost £ 11,700 66,300 Finishing cost £ 41
Yearly labour cost £ 360,000 360,000 Machining time min/part 212
Yearly interest £ 6,182.72 24,279.85 Parts per hour: Machining part/h 0.28
Yearly lab space rent £ 18,000 36,000 CNC yearly occupation time h 72,764 72,764
Yearly machine depreciation £ 72,000 63,000 CNC machine occupation rate % 1,213 1,212.7
Operational hourly rate £/h 79 96 CNC route total cost per part (ex material) £ 604 604.45
Yearly operational cost £ 472,883 574,580 CNC machines needed unit 13 13
CNC yearly operational costs £ 6,147,475 6,147,475
MANUFACTURING and MATERIAL CNC yearly production costs (ex material) £ 12,088,938 12,088,938
Alloy Ti-6Al-4V Ti-6Al-4V Yearly material costs £ 6,471,291 6,471,291
Density g/cm3 4.43 4.43 Yearly manufacturing costs £ 24,707,704 24,707,704
Material price £/kg 35.00 35.00
Scrap material price £/kg 1.60 1.60 LFW MANUFACTURING ROUTE material volume cm3 463.00
Roughing tool hourly cost £/h 84.00 Number of welds per part unit 1.00
Roughing cutting rate cm3/min 9.80 Welding cycle time min/weld 2.50
Finishing tool hourly cost £/h 250.00 Buy to Fly ratio BtF 2.8
Finishing cutting rate cm3/min 1.10 Volume of scrap material cm
3 300
Production changeover setup time h 1.00 0.15 Weight of scrap material kg 1
Finishing opeartion overthickness % 5 Estimated material purchase £ 72 72
LFW: tooling cost £ 25,000 Estimated scrap value £ 2
LFW: insert cost £ 658 Estimated material cost £ 70
LFW: insert lifespan welds 5,000 Roughing cut volume cm3 292
LFW: insert cost per weld £ 0.1 Roughing cut time min 30
Roughing tool cost £ 42
LFW POST WELDING OPERATIONS Roughing cost £ 81
PWHT 500 parts batch vacuum furnace cycle £ 550 Finishing cut volume cm3 8
PWHT batch degreasing and alpha case testing £ 150 Finishing cut time min 7
PWHT batch cost £ 700 Finishing tool cost £ 31
PWHT batch size unit 1,000 Finishing cost £ 41
PWHT unit cost £ 0.7 Machining time min/part 37
NDT reference sample cost (per part type) £ 500 Parts per hour: Machining part/h 1.61
NDT Procedure development cost £ 3,000 CNC yearly occupation time h 14,397 14,397
NDT batch size unit 700 CNC machine occupation rate % 240 239.9
NDT batch inspection cost £ 5,000 LFW route CNC cost per part (ex material) £ 129 129
NDT unit cost £ 7 CNC machines needed unit 3 3
Yearly post weld operations cost £ 156,857 CNC yearly operational costs £ 1,418,648 1,418,648
CNC yearly production costs (ex material) £ 2,585,929 2,585,929
Parts per hour: LFW part/h 24.00
LFW machine occupation time h 833 833
LFW machine occupation rate % 13.9 13.9
LFW route LFW cost per part £ 13 13
LFW route total cost per part (ex material) £ 143
LFW machines needed unit 1 1
LFW yearly operational costs £ 574,580 574,580
LFW yearly production costs (ex material) £ 268,019 268,019
Yearly material costs £ 1,393,235 1,393,235
Yearly manufacturing costs £ 6,240,412 6,240,412
TOTAL SAVINGS ON MANUFACTURING OVER 20 YEARS £ %
Material 101,561,117 78.5
Production costs 267,784,735 76.4
369,345,851 77.1
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000
Po
un
ds
Ste
rlin
g, £
Parts
CNC route costs LFW route costs
0
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
0 200 400 600 800 1,000 1,200 1,400 1,600 1,800 2,000
Po
un
ds
Ste
rlin
g, £
Parts
CNC route costs LFW route costs
Economics: MFS route vs. LFW route
Copyright © TWI Ltd 2015
LFW
Understand
Explore
Demonstrate
Transfer
Implement
Qualify
Friction and Forge Processes activities
Copyright © TWI Ltd 2015
Welding process specifications
Welding process quality records
Specification and approval of testing methods
Design codes
Specification and inspection methods
Copyright © TWI Ltd 2015
(Rotary) Friction Welding ISO 15620:2000
Friction Stir Welding of Aluminium ISO 25239:2011
Friction Stir Spot Welding ISO 18785:DRAFT
Currently no standard for LFW
Several industrials already shown interest and need to have an LFW ISO standard
We are looking to hear about your interest
ISO Standard Committee
Copyright © TWI Ltd 2015
The capability of this process is very large
We are currently just scratching the surface
We want to make it easy to understand and apply
As much as possible we want to help the market grow
Benefit everyone to have as many users as possible
Why do we do all this?
Copyright © TWI Ltd 2015
This afternoon at the end of the Conference
Welds of Ti 6Al 4V coupons
LFW Demonstration
Copyright © TWI Ltd 2015
Contact
Bertrand Flipo
Senior Project Leader
Friction and Forge Processes
Joining Group TWI Ltd
Tel: +44 (0)1223 899 000 E-mail: [email protected]
Web: www.twi-global.com