2014/9/4
1
Refill Friction Spot Joining
Hideki OkadaKawasaki Heavy Industries, Ltd., Japan
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 2
INDEX
1.Introduction
2.Process and features of FSJ
3.Evaluation of Joint properties
4. Actual prototype trial
5.Conclusion
2014/9/4
2
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 3
1.Introduction
About us, Kawasaki Heavy Industries,LTD.
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 4
1.Introduction
FSJ in Automotive industry
2014/9/4
3
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 5
1.Introduction
Rivet
FSJ attracts attention in Aerospace Industry to replace riveting technology.
FSJ
Competitive edge in techniques
Competitive edge in costs
Competitive edge in geoenvironmental impact and working environment
High flexibility in designing (e.g. FSJ spacing can be closer together) Lighter weight than rivets
Low electric consumptionVery little noise and vibration.
High productivity of FSJ leads to cost reduction.( No need to preprocessing such as drilling, deburring)Reduction in materials cost (elimination of rivets)
What is the future of aviation fastening
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 6
Retained water generated bycondensation in exit-hole can lead tocorrosion
Thin section and flash will be a fatiguebreak point
Optimized tool length is required foreach plate thickness
Exit-hole
Flash
Hook
Thin section
Basic FSJ process and disadvantages for Aircraft
1.Introduction
2014/9/4
4
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 7
2.Process and features of Refill FSJ
(2)Plunge
Plunging
Stir zone
Holding
Work
Clamp
Holding
Shoulder
Probe
(3)Re-plunge(1)Clamping and pre-heating (4)Tool removal
Work
Clamp
Holding
Shoulder
Probe
(3)Re-plunge(1)Clamping and pre-heating (4)Tool removal
Probe-Plunging
Refill FSJ process and advantages
PlungingHolding
(2)Plunge
Shoulder-Plunging
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 8
2.Process and features of Refill FSJ
PlungingHolding
Probe-PlungingRefill FSJ process and advantages
Clamping tool encloses the shoulder tool holdswork-piece tightly to prevent burring and creates a flat surface.
Probe Plunging process looks like basic FSJ.Shoulder plunging process has excellent tensile strength
In either case, refill process can make surface flat.
Plunging
Holding
Shoulder-Plunging
2014/9/4
5
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 9
2.Process and features of Refill FSJ
Cut model animation of shoulder plunging process
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 10
2.Process and features of Refill FSJ
3 servo motors in refill FSJ gun providestools rotation, shoulder and probe motions independently.
Refill FSJ gun has high Z force (up to 14.7kN) and can joinup to t4mm(Upper-sheet) of aluminum alloy and some other materials.
Refill FSJ system developed by KHI
2014/9/4
6
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 11
3.Evaluation of Joint properties
Top side surface Back side surface Joint surface is almost flat No dent on top/back surfaceJoining time is 3.7s
Joint appearance of Al2024C-T3 Alodine #1200 coated
Material Thickness SpecificationUpper sheet Al2024C-T3 .040 inch(1.02mm) AMS-QQ-A-250/5Lower sheet Al2024C-T3 .040 inch(1.02mm) AMS-QQ-A-250/5
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 12
3.Evaluation of Joint properties
Number 30Min. [N] 2702Max. [N] 3117
Average[N] 2960S.D [N] 113
C.V. [%] 3.82A value [N] 2614
122813741/8' Rivet joint [N] (MMPDS)
RSW joint [N] (MMPDS)
RefillFSJ joint
Result of tensile shear test
Tensile shear fracture modealmost specimens showed pull out fracture
Tensile shear test of Al2024C-T3 Alodine #1200 coated
0.040int 0.040int
C.V. (Coefficient of Variation) = S.D. / Average *100
2014/9/4
7
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 13
3.Evaluation of Joint properties
Evaluation of Edge DistanceED ED [mm] 6 8 10 12.5
Number 10 10 10 10Min [N] 2416 2739 2783 2919Max [N] 2879 2985 3095 3007
Average [N] 2636 2877 2966 2954
0
1000
2000
3000
4000
6 8 10 12.5
ED [mm]
Shea
r str
engt
h [N
]
Tensile shear test of Al2024C-T3 Alodine #1200 coated
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 14
3.Evaluation of Joint properties
Evaluation of Joint pitch
Pitch [mm]
Shea
r str
engt
h [N
]
0
2000
4000
6000
8000
10000
10 20 24
Pitch [mm] 10 20 24Number 10 10 10Min [N] 6997 8078 8461Max [N] 7666 8712 8911
Average [N] 7391 8520 8636
Pitch
72mm
Tensile shear test of Al2024C-T3 Alodine #1200 coated
2014/9/4
8
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 15
3.Evaluation of Joint properties
Number of Cycles
Par
cent
of s
tatic
stre
ngth
of j
oint
(%)
0.040”/0.020”0.040”/0.025”0.040”/0.032”0.040”/0.040”Spot Welding Joint (MMPDS)
125
25
25
12.5
Joint lap fatigue test of Al2024C-T3 Alodine #1200 coated
Thickness[inch]
0.020/0.040
0.025/0.040
0.032/0.040
0.040/0.040
Rifill FSJ [N](Average) 2277 2281 2249 2960
RSW [N](MMPDS) 498 658 925 1228
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 16
3.Evaluation of Joint properties
Clad material
Disappearance of interface
Φ6.11mm = SZ
Cross section of Al2024C-T3 Alodine #1200 coated
Al Cu
Cr O
Upper sheetAl2024C-T3
Lower sheetAl2024C-T3
2014/9/4
9
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 17
3.Evaluation of Joint properties
(1)Clamping and pre-heating (4)Tool removal(3)Re-plunge(2)Plunge
EPMA analysis of Al2024C-T3 Alodine #1200 coated
Cr disappeared
Cr Cr
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 18
3.Evaluation of Joint properties
Exposure time:168Hr
Al2024-T30.020”
Salt spray
Al6061-T60.025”
Apply Sealant before FSJ
Outside surface
Interfacial surface
Outside surface: UncorrodedInterfacial surface: CorrodedOutside surface: UncorrodedInterfacial surface: Uncorroded
Corrosion test of Al2024C-T3 Alodine #1200 coated
2014/9/4
10
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 19
3.Evaluation of Joint properties
Cross section and Tensile shear test of Al6061/Al2024C with sealant With
SealantWithoutSealant
Number 15 3Min [N] 2070 2229Max [N] 2383 2352
Average [N] 2211 2297
To improve corrosion resistance, joint within Sealant
A6061-T6
A2024C-T3
With sealant(Unetched)
A6061-T6
A2024C-T3
Without sealant(Etched)
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 20
3.Evaluation of Joint properties
Dissimilar joint of Aluminum and steel for Automobile
Ti-6Al-4V (1mm + 1mm)
2014/9/4
11
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 21
4. Actual prototype trial
1.Pilot door
Parts Name Thickness[mm] Material Parts Name Thickness[mm] MaterialINNER SKIN 0.635 6061-T62 DOUBLER 0.635 2024C-T3OUTER SKIN 0.635 6061-T62 DOUBLER 0.635 2024C-T3
DOUBLER 0.8128 2024C-T42 CHAMMEL 0.635 6061-T62ANGLE 0.635 2024C-T42 DOUBLER 0.635 6061-T62SPLICE 0.635 2024C-T42 DOUBLER 0.635 2024C-T42
DOUBLER 0.635 2024C-T42
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 22
4. Actual prototype trial
Fixture of this trial
1.Pilot door
2014/9/4
12
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 23
4. Actual prototype trial
Joined small parts of this trial
1.Pilot door
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 24
4. Actual prototype trial
Appearance of joined Inner/Outer SKIN
1.Pilot door
2014/9/4
13
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 25
4. Actual prototype trial
1.Pilot door
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 26
4. Actual prototype trial
with Alodine#1200
2.Frame component
ConbinationRefill FSJ
Joint lap shear strength(N)WEB-DOUBLER 2322WEB-CAP 2121
WEB-DOUBLER-CAP 3977
2014/9/4
14
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 27
4. Actual prototype trial
2.Frame component
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 28
4. Actual prototype trial
With AnodizeFaying sealant at the interface
3.Skin panel
2014/9/4
15
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 29
4. Actual prototype trial
3.Skin panel (Close-up picture)
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 30
4. Actual prototype trial
3.Skin panel (actual movie)
2014/9/4
16
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 31
5.Conclusion
Refill FSJ joint has a smooth surface without defect, flash and exit hole.
Joint lap shear strength is impressive in comparison to RSW and riveting.Even though Alodine, Chromic Acid Anodize material, and with faying sealant material.
Newly developed refill FSJ robot system can join aircraft trial parts successfully with minimal distortion.
This technology has a potential to produce parts at a high rate with high quality.
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 32
Thank you for your kind attention