« Development of Short Distance WELding Concepts for · PDF file« Development of...
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
Aeronautics Days 2006, 19-21 June 2006, Vienna
WEL-AIR project, STREP 502 832
« Development of Short Distance WELding Concepts for AIRframes »
AERONAUTICS AND SPACE Priority 4 CALL Fp6-2002-Aero-1
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
Partnership
Drivers
Aeronautical structures lightening Manufacturing cost reduction
A e r o n a u t i c a SpA
6 Aircraft manufacturers 7 Research Centres
2 University laboratories
Welded Structures Concepts
Project figures
Duration 2004-2007Budget 5 M€
INSTITUTDE
SOUDURE
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
frame
stringer
clipShort Distance Welding conceptsNew Al-alloys, FSW and LBW technologiesBehaviour specificity and performance of run-in/out
Industrial context and relevance
2001 2002 2003 2004 2005 2006 2007 2008
200
400
600
800 Szenario 1: A318 + A380
Szenario 2
Szenario 3
Num
ber o
f Wel
ded
Fuse
lage
Pane
ls
Welded stringer and clip concept on AIRBUSDevelopment of ECLIPSE concept on
FALCON and PIAGGIO P180
Project technical perimeter
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
Technical challenges
• Mechanisms and control of hot cracking in run-in/out• Fatigue and damage tolerance behaviour
New weldable and High Performance light alloysDesign of new welding concepts:
new alloys, joint design and technology (FSW)
1 - WELDING AND PROPERTY IMPROVEMENT
2 - NEW ALLOYS AND JOINT CONFIGURATIONS
3 - DAMAGE TOLERANCE ANALYSISAND DURABILITY
4 - COMPONENTS WELDING FEASABILITY
5 - BEHAVIOUR ANALYSISAND CONCEPTS VALIDATION
FULL SCALE TEST
DEMONSTRATIVE PART
CURVED PANEL TESTING
STRUCTURAL COMPONENTS DETAILS
TESTS ON STRUCTURAL DETAILS
COUPON TESTSL1
L2
L3
L4
L5
Project development
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
« Short Distance Welding Development»R&D Drivers
• Tailored welding parameters• End and clip design optimisation• Filler material feeding
• Welding tool – retractable pin • Surface preparation prior to welding
Hot cracks run-in/out Run-out and oxide
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
« Short Distance Welding Development»Key parameters and hot cracking control in LBW
Laser Start & fadingStringer ends design
Residual stresses reengineering
Micro extrusion filler wire
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
« Short Distance Welding Development»FSW short distance welding
Main welding direction
Weld start Weld stop
1
2 3Retraction of the pin
Retractable pin tool concept Welding sequence route
On-going areaRun-in Run-out
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
New alloys and joint configurationWeldability of WEL-AIR new alloys
6156, 2139, PA734, PA765
0
500000
1000000
1500000
2000000
2500000
3000000
3500000
4000000
4500000
5000000
2022 2139 6056 PA 734 PA 765New alloys
RD
G (H
ot C
rack
ing
Sus
cept
ibili
ty) No filler wire
33% 4047
HCS decreases
HCS increases
21392139
6156 6156
2139 PA765
2139 PA765
Analytical approach of hot cracking
Weldability simplified tests
T-joint concept weldability
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
New alloys and joint configurationWeldability of WEL-AIR new alloys
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
0,3
0,9
1,5
Hv mapping in skin
100-105 105-110 110-115115-120 120-125 125-130130-135 135-140 140-145
100
105
110
115
120
125
130
135
140
145
0 5 10 15 20 25 30
0,3 0,6 0,9 1,2 1,5skin: - 22 %
run-out: additional - 10 %
2024 reference conceptHigh Performance concepts
2139 T8/2139T8
2139 T8/PA765 T79
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
New alloys and joint configurationShort Distance Welds performances
Fracture in the run-out
or run-in
0
50
100
150
200
250
300
350
10 000 100 000 1 000 000Number of cycles
Max
. Stre
ss (M
Pa)
Welded specimens 2024 T32024 T3 - L-T Kt 2,3FSW w elded specimens - 2139 T82139 T8 - L-T - Kt 2,3
Comparable effect for both run-in/outMinor effect of the materialMajor effect of joint design
Major impact of the run-inMinor effect of the material and weld qualityMajor effect of joint design
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
Damage tolerance analysisSpecificity of run-in/out
-30 -20 -10 0 10 20 30
-100
-50
0
50
100
x y z
Run-in
Run-outBase plate x y z
Stre
ss [M
Pa]
y-position [mm]
-30 -20 -10 0 10 20 30
-100
-50
0
50
100
x y z
Run-in
Run-outBase plate x y z
Stre
ss [M
Pa]
y-position [mm]
Effect of the welding sequenceCrack retardation at run-inBest behaviour for run/in- 2 run-out Residual stresses re-engineering
with pocketing
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
New concepts validationConcepts and routes implementation
IN OUT IN OUT
Welded butt joints
Riveted joints
Structural details for bi-axial testing
P180 Fuselage Barrel test:Welded frames and
intercostals
Welded 4 stringer-3 clip panelsFCP & Residual Strength
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Aeronautics Days 2006, 19-21 June 2006, Vienna Improving Cost Efficiency session
Project outputs
Short distance welding procedures for stiffener-skin connections using LBW and FSW
Fatigue and Damage Tolerance behaviour of run-in/out
New High Performance Alloys combinations: Alcan Al-alloys
Behaviour analysis from basic specimen to technological components