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Copyright © TWI Ltd 2015

Bertrand Flipo Friction and Forge Processes

Linear Friction Welding Technology Update


Understand, explore, demonstrate the LFW process,

For the benefit of the wider community,

For industrial implementation,

And widespread use.

LFW technology update


17 Engineers and Technicians

Based in Cambridge

53 years of R&D in Friction Processes One of the first in Friction Welding

Pioneered Linear Friction Welding

Invented Friction Stir Welding

Friction and Forge Processes team


LFW

Understand

Explore

Demonstrate

Transfer

Implement

Qualify

Friction and Forge Processes activities


Anthony McAndrew - Presenting Contaminant Removal in Ti6Al4V

1st publication: 2013

2nd publication: 2014

Thesis: 2015

Lucie Lee Novel Industrial Applications

1st publication: 2016

2nd publication: 2017

Thesis: 2018

Modelling of LFW


Interpretation of LFW cycles

Making sense of LFW data

Correlation with HS video

Better, automated reports

Displaying relevant information

Weld record

Process analysis

Finding new ways to display difficult to grasp information

Analysis of LFW cycles: previous work


Analysis of LFW cycles: current work

TiFab – presenting

Independent monitoring of LFW cycles Helps the LFW Process Engineer in making his/her

decision

Offer evidence to support the welding operation Unobtrusive addition of sensors High sampling rate

Open, adaptable tools

Individual weld cycles (QC) Series repeatability

Project should be transferable to

other machines in the future


LFW

Understand

Explore

Demonstrate

Transfer

Implement

Qualify



Demonstrating capabilities of LFW

Core Exploration

•Joint formation mechanisms

•New materials

•Dissimilar joints

Like for like performance

•Parent metal conditioning

•Welding parameters

•Post weld heat treatments

Smart manufacture

•New parts

•Design for LFW

•Legacy components

New design freedoms

• Material tailoring

• Nested performance


Demonstration of ring manufacture Formed ring

Keystone weld

Recent industrial interest Life extension programmes

Loss of original mean of manufacture

LFW can step in to offer cost controlled replacement parts Life extension programs

of a different order of financial magnitude

Previous efforts: Legacy components


Medium to large size M16 to M60

Corrosion resistant: Ni superalloy

Made on request: Milled from solid Forged from billet

Long lead times and expensive: 4 -6 month order time Circa $200K for a bolt set

(40 bolts)

CRP2014: Bolts for sub-sea oil & gas


Welding of conditioned material

Target: API 6A718 specification

IN718: small process window

PWHT bringing back material properties to API 6A718

CRP2014: Bolts for sub-sea oil & gas

As welded After post weld heat treatment PWHT tensile

Demonstrator part


Airware 2050: latest generation Al-Cu-Li alloy for plates

Assessment of parametric conditions and joint performance: over 100 welds

“Some of the best aluminium welds ever observed”

LFW route for Airware parts

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Selected parametric conditions

Rp0.2 UTS A%


Latest generation Al-Cu-Li alloys

New Al MMCs (Al-Al2O3)

Advanced Ti MMCs (TiSiC)

Composites (GFRP, CFRP)

Combinations of the above

CRP2017: Advanced lightweight materials

Courtesy of Tisics


Smart manufacture


Monolithic, large structures Go beyond large forging sizes Maintain throughput capability Part count reduction Knock on benefits in maintenance

Nested performance Combine LFW with other high-end

processes for component performance

Material tailoring Strategic placement of dissimilar

alloys Embed features Enable use of smart materials Further costs control

LFW: New design freedoms

Ti6246

Ti64

Potential Example:

Courtesy of Airbus


LFW

Understand

Explore

Demonstrate

Transfer

Implement

Qualify



Aerospace events

Introduce: badly known process

Inform

Update

Training Courses

IWE courses

On-demand Process training

Sponsored projects

Government / EU

Industry

LFW Technology Transfer


The leading LFW event in the World

Growing interest

TWI’s Biennial Int’l LFW Symposium

Contact: [email protected]

2015

2013

2011


Description\ Route Units CNC LFW Description\ Route Units CNC yearly LFW yearly Component

OPERATIONAL COSTS Volume of finished part cm3 163.00

Working weeks per year week 50 50 Yearly rate of production unit 20,000

Weekly working hours h/week 120 120

Yearly production hours h/year 6,000 6,000 CNC MANUFACTURING ROUTE material volume cm3 2179.00

Yearly rate of production unit 20,000 20,000 Buy to fly ratio BtF 13.4

Production batch size unit 10 10 Volume of scrap material cm3 2,016

Production life year 20 20 Weight of scrap material kg 9

Purchase price per machine £ 400,000 1,400,000 Estimated material purchase per part £ 338

Machine economic life year 5 20 Estimated scrap value per part £ 14

Yearly interest rate % 1.5 1.5 Estimated material cost per part £ 324

Depreciation rate (over economic life) % 90 90 Roughing cut volume cm3 2,008

Nominal power kWh 15 85 Roughing cut time min 205

Electricity rate £/kWh 0.13 0.13 Roughing tool cost £ 287

Workshop floor occupation m2 50 100 Roughing cost £ 556

Monthly workshop rental rate £/m2 30 30 Finishing cut volume cm

3 8

Labour cost £/h 60 60 Finishing cut time min 7

Yearly maintenance cost £ 5,000 25,000 Finishing tool cost £ 31

Yearly energy usage cost £ 11,700 66,300 Finishing cost £ 41

Yearly labour cost £ 360,000 360,000 Machining time min/part 212

Yearly interest £ 6,182.72 24,279.85 Parts per hour: Machining part/h 0.28

Yearly lab space rent £ 18,000 36,000 CNC yearly occupation time h 72,764 72,764

Yearly machine depreciation £ 72,000 63,000 CNC machine occupation rate % 1,213 1,212.7

Operational hourly rate £/h 79 96 CNC route total cost per part (ex material) £ 604 604.45

Yearly operational cost £ 472,883 574,580 CNC machines needed unit 13 13

CNC yearly operational costs £ 6,147,475 6,147,475

MANUFACTURING and MATERIAL CNC yearly production costs (ex material) £ 12,088,938 12,088,938

Alloy Ti-6Al-4V Ti-6Al-4V Yearly material costs £ 6,471,291 6,471,291

Density g/cm3 4.43 4.43 Yearly manufacturing costs £ 24,707,704 24,707,704

Material price £/kg 35.00 35.00

Scrap material price £/kg 1.60 1.60 LFW MANUFACTURING ROUTE material volume cm3 463.00

Roughing tool hourly cost £/h 84.00 Number of welds per part unit 1.00

Roughing cutting rate cm3/min 9.80 Welding cycle time min/weld 2.50

Finishing tool hourly cost £/h 250.00 Buy to Fly ratio BtF 2.8

Finishing cutting rate cm3/min 1.10 Volume of scrap material cm

3 300

Production changeover setup time h 1.00 0.15 Weight of scrap material kg 1

Finishing opeartion overthickness % 5 Estimated material purchase £ 72 72

LFW: tooling cost £ 25,000 Estimated scrap value £ 2

LFW: insert cost £ 658 Estimated material cost £ 70

LFW: insert lifespan welds 5,000 Roughing cut volume cm3 292

LFW: insert cost per weld £ 0.1 Roughing cut time min 30

Roughing tool cost £ 42

LFW POST WELDING OPERATIONS Roughing cost £ 81

PWHT 500 parts batch vacuum furnace cycle £ 550 Finishing cut volume cm3 8

PWHT batch degreasing and alpha case testing £ 150 Finishing cut time min 7

PWHT batch cost £ 700 Finishing tool cost £ 31

PWHT batch size unit 1,000 Finishing cost £ 41

PWHT unit cost £ 0.7 Machining time min/part 37

NDT reference sample cost (per part type) £ 500 Parts per hour: Machining part/h 1.61

NDT Procedure development cost £ 3,000 CNC yearly occupation time h 14,397 14,397

NDT batch size unit 700 CNC machine occupation rate % 240 239.9

NDT batch inspection cost £ 5,000 LFW route CNC cost per part (ex material) £ 129 129

NDT unit cost £ 7 CNC machines needed unit 3 3

Yearly post weld operations cost £ 156,857 CNC yearly operational costs £ 1,418,648 1,418,648

CNC yearly production costs (ex material) £ 2,585,929 2,585,929

Parts per hour: LFW part/h 24.00

LFW machine occupation time h 833 833

LFW machine occupation rate % 13.9 13.9

LFW route LFW cost per part £ 13 13

LFW route total cost per part (ex material) £ 143

LFW machines needed unit 1 1

LFW yearly operational costs £ 574,580 574,580

LFW yearly production costs (ex material) £ 268,019 268,019

Yearly material costs £ 1,393,235 1,393,235

Yearly manufacturing costs £ 6,240,412 6,240,412

TOTAL SAVINGS ON MANUFACTURING OVER 20 YEARS £ %

Material 101,561,117 78.5

Production costs 267,784,735 76.4

369,345,851 77.1

0

5,000,000

10,000,000

15,000,000

20,000,000

25,000,000

30,000,000

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000

Po

un

ds

Ste

rlin

g, £

Parts

CNC route costs LFW route costs

0

500,000

1,000,000

1,500,000

2,000,000

2,500,000

3,000,000

0 200 400 600 800 1,000 1,200 1,400 1,600 1,800 2,000

Po

un

ds

Ste

rlin

g, £

Parts

CNC route costs LFW route costs

Economics: MFS route vs. LFW route


LFW

Understand

Explore

Demonstrate

Transfer

Implement

Qualify



Welding process specifications

Welding process quality records

Specification and approval of testing methods

Design codes

Specification and inspection methods


(Rotary) Friction Welding ISO 15620:2000

Friction Stir Welding of Aluminium ISO 25239:2011

Friction Stir Spot Welding ISO 18785:DRAFT

Currently no standard for LFW

Several industrials already shown interest and need to have an LFW ISO standard

We are looking to hear about your interest

ISO Standard Committee


The capability of this process is very large

We are currently just scratching the surface

We want to make it easy to understand and apply

As much as possible we want to help the market grow

Benefit everyone to have as many users as possible

Why do we do all this?


This afternoon at the end of the Conference

Welds of Ti 6Al 4V coupons

LFW Demonstration


Contact

Bertrand Flipo

Senior Project Leader

Friction and Forge Processes

Joining Group TWI Ltd

Tel: +44 (0)1223 899 000 E-mail: [email protected]

Web: www.twi-global.com

mailto:[email protected]

http://www.twi-global.com/



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