D. Stephen Cater TWI LTD
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Transcript of D. Stephen Cater TWI LTD
Friction Stir Weldingforfor
Marine ConstructionMarine Construction
Stephen Cater
TWI Ltd United KingdomTWI Ltd, United KingdomTel: +44 114 269 9046,
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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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