Santos Vilaca da Silva, Pedro Friction Stir Welding and its Variants … · 6 Materials Joining and NDT Department of Engineering Design and Production Friction Stir Welding Process

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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

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and Production

Friction Based Technology Sample of Processes

Friction Welding Friction Linear Welding


and Production


Friction Extrusion Friction Hydro Pillar Friction Riveting

Movies/FHPP.mpg

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and Production


FS Production of

Functionally Graded Materials (FGM)

FS for Built-Up

Friction Surfacing


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

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and Production

Friction Stir Welding Process Fundaments and Parameters


and Production

Friction Stir Welding Process Fundaments – Joint Design

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Friction Stir Welding Process Fundaments – Example of Joints

SPIF of tailored blanks welded by FSW


and Production

Friction Stir Welding Process Fundaments – Clamping System

Advanced Automatized Solutions

Conventional Solutions

Vacuum

Hydraulic

Magnetic

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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


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

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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


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 %

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and Production

Industrial Application to Al Alloys Aeronautic Industry

Eclipse Aviation @ USA

Wing

Fuselage


and Production

Industrial Application to Al Alloys Aeronautic Industry

Courtesy/Source: TWI

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Industrial Application to Al Alloys Aeronautic Industry – Data for AA2024-T351 (t=4 mm)

(R=0

)


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

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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


and Production

Industrial Application to Al Alloys Automotive Industry

Center Tunnel for

AUDI R8 Le Mans


Courtesy/Source: HZG

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and Production

Industrial Application to Al Alloys Automotive Industry

Aluminium 2002 Fair in Germany

@ SAPA stand



and Production

Industrial Application to Al Alloys Railway Industry

A-Train concept from

Hitachi, Ltd @ Japan for

rolling stock based on FSW

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and Production

Industrial Application to Al Alloys Railway Industry

UFF/Cullen Audit Report by Ladbroke Grove Inquiry recommended the

application of FSW replacing MIG


and Production

Industrial Application to Al Alloys Informatics Industry

Apple 21.5 and 27-inch iMACs 2012 @ USA

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and Production

Industrial Application Al Alloys Electrical Industry

Electrical Transformers Bobbin's – SIEMENS @ Portugal


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

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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)


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

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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


and Production

Industrial Application to Steel Shipbuilding Industry

Aalto U belongs to Advisory Group of HILDA project:

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and Production

Industrial Application to Steel Shipbuilding Industry (source: HILDA project)

FSW… Aims to avoid This!

Courtesy / Source: TWI


and Production


FSW Tool: a major challenge ! …Materials and Life Assessment


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and Production


FSWelding and FSProcessing:



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)

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and Production

Industrial Application to Cu Nuclear Fuel and Waste Management (Posiva + SKB)


and Production

Friction Stir Welding

Based Innovations

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and Production

Friction Stir

Based Innovations

4th December 2014 Tampere, Finland

Thank You / Kiitos / Tack

Department of Engineering

Design and Production

Documents

Santos Vilaca da Silva, Pedro Friction Stir Welding and its Variants … · 6 Materials Joining and NDT Department of Engineering Design and Production Friction Stir Welding Process