Presentación del ponente D. Stephen Cater TWI LTD, Technology Engineering, en la Jornada Transnacional "Demostración Tecnológica en la Industria Auxiliar del Naval" Realizada el 26 de enero de 2010, en Santiago de Compostela

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
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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
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6. FSW Principle

7. FSW Principle

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
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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. 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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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
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21. 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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22. FSW Modules for Kleven Verft’s “Finnmarken”
Photos: Thomas Müller, 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
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24. 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

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)
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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…
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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.
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