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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