Friction Stir Weldingforfor

Marine ConstructionMarine Construction

Stephen Cater

TWI Ltd United KingdomTWI Ltd, United KingdomTel: +44 114 269 9046,

stephen.cater@twi.co.uk

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Aluminium in ships – where and why ?Wh l i ht i d d d f l ffi i• When low weight, increased speed and fuel efficiency are required:

• Pleasure boats and large yachts• Patrol boats for custom, police, coast guard• Accommodation modules, cabins• Helicopter decksHelicopter decks• Hovercrafts• High speed ferries• Cruise ships superstructure• Fast intervention naval craft

Aluminium – issues to be consideredSt t l I t it• Structural Integrity– Fatigue performance differs from that of steel– Different design codes are requiredg q

• Corrosion performanceSelection of correct alloy– Selection of correct alloy

– Attention to detail in design and elimination of corrosion pockets

• Fabrication– Aluminium is lighter than steel and so requires less craneage– Aluminium is regarded as more difficult to weld than steel– Aluminium is regarded as more difficult to weld than steel

FSW P t t d b TWIFSW Patented by TWI

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FSW Principle

FSW Principle

Process advantages

• Excellent in strength, fatigue, corrosionV l di t ti• Very low distortion

• Automated process – consistent quality• No fume no radiation no noiseNo fume, no radiation, no noise• Single pass process, even for thick sections• Cost benefits – no filler, no gas, low labour costs

FSW of 50 and 75mm thick AA6082-T6

50mm

75mm75mm75mm

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20mm Section plate trials AA201720mm Section plate trials AA2017Mid Section

HV 120

140

160

180

-80 -60 -40 -20 0 20 40 60 80

Har

dnes

s,

20

40

60

80

100

ASRS

om,m

m

18

Distance from the center, mm

Distance, mm vs Hardness, HV

Rpm=300

ASRS

from

the

botto

68

1012141618

120 130 140 150 160

Speed=100mm/min

Distance frm weld center, mm

-40 -30 -20 -10 0 10 20 30 40

Dis

tanc

e f

24 170

RS AS

20mm Section plate trials AA508320mm Section plate trials AA5083100

Har

dnes

s, H

V

40

60

80

Mid Section

Distance frm weld center, mm

-150 -100 -50 0 50 100 15020

40

Distance(mm) vs Hardness (HV) ASRS

Rpm= 300 m, m

m

18 86

Distance(mm) vs Hardness (HV) ASRS

Speed=80mm/min

from

the

botto

68

1012141618 86

88 90 92 94 96 98

Distance from weld center, mm

-40 -30 -20 -10 0 10 20 30 40

Dis

tanc

e f

24 100

102

RS AS

20mm Section plate trials AA6082Mid Section

20mm Section plate trials AA6082

, HV

1 0 0

1 2 0

1 4 0

1 6 0

D i t f l d t

- 6 0 - 4 0 - 2 0 0 2 0 4 0 6 0

Har

dnes

s

2 0

4 0

6 0

8 0

ASRS

Rpm= 500,

D i s t a n c e f r o m w e l d c e n t e r , m m

d i s t a n c e ( m m ) v s H a r d n e s s ( H V )

ASRS

ttom

, mm

141618

70 80

Speed=350mm/min

nce

from

bot

468

101214 80

90 100 110 120 130

Distance from weld center,mm

-40 -30 -20 -10 0 10 20 30 40Dis

ta 2130 140

RS AS

20mm Section plate trials AA702020mm Section plate trials AA7020Mid Section

ess,

HV

1 00

120

140

160

D is ta n ce frm w e ld ce n te r m m

-80 -60 -40 -20 0 20 40 60 80

Har

dne

2 0

40

60

80

ASRS

ttom

,mm

141618

D is ta n ce frm w e ld ce n te r, m m

D is tance (m m ) vs H a rdness (H V )

Rpm= 200

ASRS

ce fr

om th

e bo

t

468

101214 100

110 120 130 140

Speed=90mm/min

Distance from weld center, mm

-60 -40 -20 0 20 40 60Dis

tan

24

RS AS

350 35%

Properties of FSW in AA6082

301

254

300260

244

310

250

300

350M

Pa]

25%

30%

35%

%]

22.9%

18.8%200

250

tren

gh [

20%

25%

gatio

n [%

10.4%

6 4%

9.9%100

150

Tens

ile S

10%

15%

Elon

g

4.9%6.4%

0

50T

0%

5%

T6Parent

T6FSW

T6FSW &

aged

T4Parent

T4FSW

T4FSW &

agedTensile strength MPa Elongation %

1000

Fatigue Results for FSW Butt Joints

100nge,

MPa 7075 welded

7075 plate2014 welded2014 l t100

Stre

ss ra

n 2014 plate2219 welded2219 plate5083 weldedECCS Class B35083 plate

10

Endurance, cycles104 105 106 107 108

Design S-N Curves for AA6005

FSW approvals

• Lloyds Register• DNV• Bureau Veritas• RINA

ABS• ABS• Germanisher Lloyd• TUVTUV• DB• FAA

FSW hi b ildi li ti i E USAFSW shipbuilding applications in Europe, USA, Japan, Australia and China

Sapa’s Deep Freezing Panels for Pressing Fish BlocksSapa s Deep Freezing Panels for Pressing Fish Blocks

2 Photos: Backlund J et al: ‘FSW - Weld Properties and Manufacturing Techniques’. Inalco 98

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FSW panels for Hovercraft at Aluminium Shipbuilders Ltd in EnglandFSW panels for Hovercraft at Aluminium Shipbuilders Ltd in England

FSW FSW

FSW D kFSW D k

BulkheadBulkheadPanelPanel

FSW DeckFSW DeckPanelPanel

Griffon 8000Griffon 8000Quarterdeck HovercraftQuarterdeck Hovercraft

80 seat, 880 seat, 8--10t payload 10t payload for Incheon Airport Korea1for Incheon Airport Korea1

Photos: Norsk Hydro UK Ltd, Aluminium Shipbuilders Ltdand Griffon Hovercraft www.griffonhovercraft.com

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FSW Modules for “Seven Seas Navigator”FSW Modules for Seven Seas Navigator

3 Photographs: Hydro Marine Aluminium3 Photographs: Hydro Marine Aluminium

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FSW Modules for Kleven Verft’s “Finnmarken”

Photos: Thomas Müller, http://www.norwegen-freunde.com/thomasm/skip_finnmarken03.htmhttp://www.norwegische-postschiffe.de/hr_skip_ms_finnmarken02.htm & http://www.ham.no

Nichols Bros & Advanced Joining Technologies:

X-Craft ‘Sea Fighter’ for US Navy

Nichols BrosNichols Bros AJTAJT

Photos: Photos: www.nicholsboats.com and www.ajtwww.nicholsboats.com and www.ajt--inc.cominc.com

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FSW t M i Al i i Off h M d lFSW at Marine Aluminium - Offshore Modules

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Photos: www.marine-aluminium.com

FSW at China FSW CentreFSW at China FSW Centre

12m

5m

www.cfswt.com

FSW and High Energy Rate Formingg gy gby RFI, Univ of Adelaide and TWI

2 Photos: http://www.management-consultants.com.au/members/profile.asp?who=19DE10E86E90C46DC0AEADF5EF3ED42431343636

Current Research and Development

• Improved tool designs• Portable low cost machines• Portable, low cost machines• FSW of Steel, Titanium• FSW of thick section Al (LNG applications)• FSW of dissimilar materials• Friction Stir Processing

S f• FSW for more complex shapes

SSFSW f Ti A li tiButt welds have recently been made at welding speeds f t 200 / i

SSFSW of Ti - Applications

of up to 200mm/min:

6.35mm Ti-6Al-4V welded at 100mm/min

6 356.35mm Ti-6Al-4V welded atwelded at 200mm/min

TWI Trial on FSW of Al to Steel (Mechanical Interlock)TWI Trial on FSW of Al to Steel (Mechanical Interlock)

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St ti Sh ld FSWStationary Shoulder FSW

AA6082 T6 6 bAA6082-T6 6mm probe

Stationary Shoulder FSWThi k S ti W ldThick Section Weld

AA6082-T6 30mm probe

Stationary Shoulder Corner FSW

NLM Japanese Patent : 11-320128

Stationary Shoulder Corner FSW

AA6082-T6 6mm probeNLM Japanese Patent : 11-320128

Stationary Shoulder Corner FSWTee Welding Schematicg

Rotating Pin

Profiled static shoulder

WorkpieceWorkpieceWorkpiece

Support

NLM Japanese Patent : 11-320128

Stationary Shoulder Corner FSW

NLM Japanese Patent : 11-320128

St ti Sh ld C FSWStationary Shoulder Corner FSW

8 thi k l t 6082 T6 T8mm thick plate 6082-T6 Tee Weld

NLM Japanese Patent : 11-320128

Stationary Shoulder Corner FSWStationary Shoulder Corner FSWDissimilar Alloy Tee Weld

AA7075-T6

AA2014-T6

NLM Japanese Patent : 11-320128

Stationary Shoulder Corner FSWFORCE FORCE

Mechanical Testing JigNLM Japanese Patent : 11-320128

Stationary Shoulder Corner FSW6082-T6 310MPa

Force = 50kN

UTS = 230MPaUTS = 230MPa

Efficiency 75%

8mm thick plate 6082-T6 Tee WeldNLM Japanese Patent : 11-320128

St ti Sh ld C FSWStationary Shoulder Corner FSWEXTERNAL CORNER

WELDING

Rotating Pin

Profiled static shoulder

orkpie

ce

Workpie

Wor

piece

Support

• Many commercial applications of Friction Stir Welding in

Conclusionsy pp g

shipbuilding worldwide

• WPS or component approvals by major classification societies

• 193 licensees worldwide, 1600 patent applications

Process will be used more when its advantages are appreciated by• Process will be used more when its advantages are appreciated by naval architects and designers

– High quality mechanised welds with no consumablesHigh quality, mechanised welds with no consumables

– No corrosion traps

Hi h j i t ffi i– High joint efficiency

– Can join dissimilar alloys – ie 6XXX to 5XXX or 2XXX or 7XXX…

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Future Collaboration

• In 2010 the EU may call for proposals from SME Associations for collaborative research under the Framework 7 programme.

• TWI would be pleased to work with a consortium of shipbuilding SMEs to submit a research proposal to further develop friction stir welding for the benefit of the Europeandevelop friction stir welding for the benefit of the European maritime sector.

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