FRICTION STIR WELDING

Torben Lorentzen
CEO of DanStir ApS Danish Stir Welding Technology & Friction Stir Welding Specialist Bayards Aluminium Construction B.V.

Out-line
Friction Stir Welding
- The proces in brief - Weld properties

Legal Aspects
- Licensees - Patents - Standards

Friction Stir Welding at BAYARDS

- Equipment functionality and capabilities - Applications

Friction Stir Welding

- The proces in brief - Weld properties

The sequences of a Friction Stir Welding event

Micro-structural effect of a Friction Stir Welding event

S tr e s s ( M Pa ) 130 120 110 100 90 80 70 60 50 40 30 20 10 0 0

B
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 S t r a in ( % )

Tensile test behaviour; EN-AW-6082-O

120 110 100 90

Hardness [HV10]

80 70 60 50 40 30 20 10 0 -5 0 5 10 15 20 25 30 35

No. 22

Position [mm]

Hardness profile; EN-AW-6082-T6

Heat treatable alloys recovering hardness over time here EN-AW-7075

Post weld heat treatment (PWHT) recovering essentially to parent metal hardness here EN-AW-6082-T6

Material 5083-O Parent 5083-O FSW 5083-H321 Parent 5083-H321 FSW 6082-T6 Parent 6082-T6 FSW 6082-T6 FSW & aged 6082-T4 Parent 6082-T4 FSW 6082-T4 FSW & aged 7108-T79 Parent 7108-T79 FSW 7108-T79 FSW & aged

0.2% Proof strength [MPa] 148 141 249 153 286 160 274 149 138 285 295 210 245

Tensile strength [MPa] 298 298 336 305 301 254 300 260 244 310 370 320 350

Elongation [%] 23,5 23 16,5 22,5 10,4 4,9 6,4 22,9 18,8 9,9 14,0 12,0 11,0

Welding factor [UTS-FSW / UTS-Parent]

1,00

0,91

0,83 1,00

0,93 1,19

0,86 0,95

Weld properties for a range of common alloys

Refined micro-structure and good surface finish

High weld ductility renders good bending performance

Legal Aspects
- Licensees - Patents - Standards

Licensee status :

Smith, I. J., 2008, FSW Patents A Stirring Story, TWI

Development in licensees over the past 14 years

Country Germany France Belgium The Netherlands

Non-commercial 5 3 2 0

Commercial 9 2 1 1

Licensees in an around The Netherlands

Patent status :
The two original patents held by TWI covers the intellectual property rights regarding the general use of the technology:

US-5,460,317 / EPO615480B1 (1992-2012) US-5,813,592 / EPO752926B1 (1995-2015)

Patent status :

Smith, I. J., 2008, FSW Patents A Stirring Story, TWI

Development in 3rd party patent filings

Patent status :

Top-10 organisations holding the most Friction Stir Welding patents

Smith, I. J., 2008, FSW Patents, A Stirring Story, TWI

Company Hitachi Boeing KHI Showa NLM SLM Mazda Lockheed Martin ESAB MHI

Total (US/EP/JP) 215 69 44 44 35 23 13 9 9 9

Standards status :
Friction Stir Welding is approved by most of the classification bodies including:

American Bureau of Shipping (ABS) Bureau Veritas (BV) Det Norske Veritas (DNV) Germanischer Lloyds (GL) Lloyds Register of Shipping (LRS) Registro Italiano Navale (RINA)

Standards status :
An official international standard is under development by the B1 Working Group of the IIW Commission III :

ISO/AWI-25239 Part 1-5:

ISO/AWI 25239-1: Part 1: Vocabulary ISO/AWI 25239-2: Part 2: Design of welded joints ISO/AWI 25239-3: Part 3: Qualification of welding operators ISO/AWI 25239-4: Part 4: Specification and qualification of welding procedures ISO/AWI 25239-5: Part 5: Quality and inspection requirements

Friction Stir Welding at BAYARDS

- Equipment functionality and capabilities - Applications

Equipment :

The Friction Stir Welding installation at BAYARDS Aluminium Constructions B.V.

Equipment :
- Envelope 3.5 x 15.5 meter - 100 kN down force - Position- or load-control - 2D-programable weld paths - Maximum daylight 1.6 meters - Prepared for a 2nd weld head

Applications :

- Tailor Welded Blanks (TWB) - Aircraft cargo floor panels - Leight weight fuel tanks for UAV - X-ray scanner parts

Tailor Welded Blanks (TWB) :

Tailor Welded Blanks welded for Renault inner door panels

Aircraft cargo floor panels :

Cargo floor panels for Lockheed Martin C-130 Hercules aircraft

Leight weight fuel tanks for UAV :

Light weight fuel tanks for un-maned air crafts

X-ray scanner parts :

C-arc beams for Philips medical X-ray scanning equipment

Torben Lorentzen