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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
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
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
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
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
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
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
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
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
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
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
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
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