D. Stephen Cater TWI LTD
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The document discusses the advantages and applications of Friction Stir Welding (FSW) in marine construction, particularly for aluminum structures. It highlights FSW's strengths in terms of low distortion, automation, and superior strength and corrosion resistance compared to traditional welding methods. The text also emphasizes current research directions aimed at improving FSW technology and its potential future applications in the shipping industry.
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Properties of FSW in AA6082
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Tensile strength MPa Elongation %](https://image.slidesharecdn.com/3stephencatertwiltd-110614040334-phpapp01/85/D-Stephen-Cater-TWI-LTD-14-320.jpg)
D. Stephen Cater TWI LTD
- 2. Friction Stir Welding forfor Marine ConstructionMarine Construction Stephen Cater TWI Ltd United KingdomTWI Ltd, United Kingdom Tel: +44 114 269 9046, stephen.cater@twi.co.uk swk
- 3. 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
- 4. Aluminium issues to be considered St t l I t it Structural Integrity Fatigue performance differs from that of steel Different design codes are requiredg q Corrosion performance Selection 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
- 5. FSW P t t d b TWIFSW Patented by TWI swk
- 8. Process advantages Excellent in strength, fatigue, corrosion V 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
- 9. FSW of 50 and 75mm thick AA6082-T6 50mm 75mm75mm 75mm swk
- 10. 20mm Section plate trials AA201720mm Section plate trials AA2017 Mid Section HV 120 140 160 180 -80 -60 -40 -20 0 20 40 60 80 Hardness, 20 40 60 80 100 ASRS om,mm 18 Distance from the center, mm Distance, mm vs Hardness, HV Rpm=300 ASRS fromthebotto 6 8 10 12 14 16 18 120 130 140 150 160 Speed=100mm/min Distance frm weld center, mm -40 -30 -20 -10 0 10 20 30 40 Distancef 2 4 170 RS AS
- 11. 20mm Section plate trials AA508320mm Section plate trials AA5083 100 Hardness,HV 40 60 80 Mid Section Distance frm weld center, mm -150 -100 -50 0 50 100 150 20 40 Distance(mm) vs Hardness (HV) ASRS Rpm= 300 m,mm 18 86 Distance(mm) vs Hardness (HV) ASRS Speed=80mm/min fromthebotto 6 8 10 12 14 16 18 86 88 90 92 94 96 98 Distance from weld center, mm -40 -30 -20 -10 0 10 20 30 40 Distancef 2 4 100 102 RS AS
- 12. 20mm Section plate trials AA6082 Mid 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 Hardness 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 14 16 18 70 80 Speed=350mm/min ncefrombot 4 6 8 10 12 14 80 90 100 110 120 130 Distance from weld center,mm -40 -30 -20 -10 0 10 20 30 40 Dista 2 130 140 RS AS
- 13. 20mm Section plate trials AA702020mm Section plate trials AA7020 Mid Section ess,HV 100 120 140 160 D istance frm w eld center m m -80 -60 -40 -20 0 20 40 60 80 Hardne 20 40 60 80 ASRS ttom,mm 14 16 18 D istance frm w eld center, m m D istance (m m ) vs H ardness (H V ) Rpm= 200 ASRS cefromthebot 4 6 8 10 12 14 100 110 120 130 140 Speed=90mm/min Distance from weld center, mm -60 -40 -20 0 20 40 60 Distan 2 4 RS AS
- 14. 350 35% Properties of FSW in AA6082 301 254 300 260 244 310 250 300 350MPa] 25% 30% 35% %] 22.9% 18.8%200 250 trengh[ 20% 25% gation[% 10.4% 6 4% 9.9%100 150 TensileS 10% 15% Elong 4.9% 6.4% 0 50 T 0% 5% T6 Parent T6 FSW T6 FSW & aged T4 Parent T4 FSW T4 FSW & aged Tensile strength MPa Elongation %
- 15. 1000 Fatigue Results for FSW Butt Joints 100 nge,MPa 7075 welded 7075 plate 2014 welded 2014 l t100 Stressran 2014 plate 2219 welded 2219 plate 5083 welded ECCS Class B3 5083 plate 10 Endurance, cycles 104 105 106 107 108
- 16. Design S-N Curves for AA6005
- 17. FSW approvals Lloyds Register DNV Bureau Veritas RINA ABS ABS Germanisher Lloyd TUVTUV DB FAA
- 18. FSW hi b ildi li ti i E USAFSW shipbuilding applications in Europe, USA, Japan, Australia and China
- 19. Sapas 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 swk
- 20. FSW panels for Hovercraft at Aluminium Shipbuilders Ltd in EnglandFSW panels for Hovercraft at Aluminium Shipbuilders Ltd in England FSWFSW FSW D kFSW D k BulkheadBulkhead PanelPanel FSW DeckFSW Deck PanelPanel Griffon 8000Griffon 8000 Quarterdeck HovercraftQuarterdeck Hovercraft 80 seat, 880 seat, 8--10t payload10t payload for Incheon Airport Korea1for Incheon Airport Korea1 Photos: Norsk Hydro UK Ltd, Aluminium Shipbuilders Ltd and Griffon Hovercraft www.griffonhovercraft.com swk
- 21. FSW Modules for Seven Seas NavigatorFSW Modules for Seven Seas Navigator 3 Photographs: Hydro Marine Aluminium3 Photographs: Hydro Marine Aluminium swk
- 22. FSW Modules for Kleven Verfts Finnmarken Photos: Thomas M端ller, http://www.norwegen- freunde.com/thomasm/skip_finnmarken03.htm http://www.norwegische-postschiffe.de/hr_skip_ms_finnmarken02.htm & http://www.ham.no
- 23. 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 swk
- 24. FSW t M i Al i i Off h M d lFSW at Marine Aluminium - Offshore Modules swk Photos: www.marine-aluminium.com
- 25. FSW at China FSW CentreFSW at China FSW Centre 12m 5m www.cfswt.com
- 26. FSW and High Energy Rate Formingg gy g by RFI, Univ of Adelaide and TWI 2 Photos: http://www.management-consultants.com.au/members/ profile.asp?who=19DE10E86E90C46DC0AEADF5EF3ED42431343636
- 27. 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
- 28. SSFSW f Ti A li ti Butt 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
- 29. TWI Trial on FSW of Al to Steel (Mechanical Interlock)TWI Trial on FSW of Al to Steel (Mechanical Interlock) swk
- 30. St ti Sh ld FSWStationary Shoulder FSW AA6082 T6 6 bAA6082-T6 6mm probe
- 31. Stationary Shoulder FSW Thi k S ti W ldThick Section Weld AA6082-T6 30mm probe
- 32. Stationary Shoulder Corner FSW NLM Japanese Patent : 11-320128
- 33. Stationary Shoulder Corner FSW AA6082-T6 6mm probe NLM Japanese Patent : 11-320128
- 34. Stationary Shoulder Corner FSW Tee Welding Schematicg Rotating Pin Profiled static shoulder WorkpieceWorkpiece Workpiece Support NLM Japanese Patent : 11-320128
- 35. Stationary Shoulder Corner FSW NLM Japanese Patent : 11-320128
- 36. 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
- 37. Stationary Shoulder Corner FSWStationary Shoulder Corner FSW Dissimilar Alloy Tee Weld AA7075-T6 AA2014-T6 NLM Japanese Patent : 11-320128
- 38. Stationary Shoulder Corner FSW FORCE FORCE Mechanical Testing Jig NLM Japanese Patent : 11-320128
- 39. Stationary Shoulder Corner FSW 6082-T6 310MPa Force = 50kN UTS = 230MPaUTS = 230MPa Efficiency 75% 8mm thick plate 6082-T6 Tee Weld NLM Japanese Patent : 11-320128
- 40. St ti Sh ld C FSWStationary Shoulder Corner FSW EXTERNAL CORNER WELDING Rotating Pin Profiled static shoulder orkpiece W orkpie W or piece Support
- 41. Many commercial applications of Friction Stir Welding in Conclusions y 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 swk
- 42. 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. swk