friction stir welding (fsw) and hybrid laser welding (hlw) of€¦ · friction stir welding...
TRANSCRIPT
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Friction Stir Welding (FSW) and Hybrid Laser Welding (HLW) of Ti 6-4 Structural Components
Tim TrappPrograms Manager – Government Programs Office
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Acknowledgements
This work was completed under Army Contract # DAAD19-03-2-002 to investigate joining of complex structures using new advanced processes combined with modular tooling for rapid prototyping.
EWI Staff:Jeff Bernath − FSWSeth Krem − Tooling Tim Li − FSWBrandon Shinn − HLWTim Trapp − Project Manager
Army Research Laboratory:Walter Roy − Program Manager
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Outline
Objectives
EWI facilities
Fixturing approach – Demmeler tooling
Tool design for FSW of Ti 6-4
Welding Ti 6-4 structural geometries
Comparison of FSW, HLW and GMAW-P processes
Fabrication of titanium structures
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Objectives
Develop the FSW process for structure applications for the Army’s Future Combat System (FCS)
Produce single pass, full penetration FSW in Ti 6-4 up to ½-in. thick
Fabricate a Ti 6-4 structure using FSW, HLW and Demmeler tooling
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EWI Facilities
Conceptual model of manufacturing cell
The Army Research Lab
• 10’ x 10’ x 24’ working envelo pe• 35,000 lb axial plun ge capacit y• 7 coordin ated axes• ARL spon sored• Manufactured by Gen eral Too l Compan y
(Cincinn ati, OH)
Friction Stir Welding Facility
• 10’ x 14’ x 36’ working envelo pe • Arc/laser /h ybrid laser weld ing
system• Fanuc 120i robot an d Lin coln
Po werwaveTM
• 9 coordin ated axes• ARD EC sponsored• Manufactured b y Hawk
Techn olog y, Ltd . (Rock Island , IL)
Robotic Arc Welding Facility
Additional features (not shown)
• Shared work surface (19.5’ x 12’) utilizing Demmeler system
• 5’ x 10’ Demmeler table with modular tooling package
• Romer portable CMM
• Rotary-ti lt weld ing position er
Flexible Manufacturing Facility
FSW and robotic arc gantries at EWI with Demmeler tooling bed
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Demmeler Tooling
Tooling designed for rapid prototyping with a high degree of accuracy– Precision bored tooling with a hole to hole spacing tolerance of 0.001"– Eliminates need for lengthy set up times by avoiding indexing,
shimming and fit up issues– Common parts keep prices low and tooling adaptable for new uses
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Tool Material Selection for FSW of Ti 6-4
Multi-year study comparing nine (9) different tool materials for FSW of Ti 6-4 – Compromise of tool cost vs. tool life– Cost Ranking (Least to Greatest) AE-5 & AE-6, AE-7 & AE-8, AE-9
(GE patented tool material, ref. US Patent No. 7,032,800)
0.000
0.005
0.010
0.015
0.020
0.025
0.030
0.035
0.040
0 2,000 4,000 6,000 8,000 10,000 12,000 14,000Maximum Z Load during Welding (lbs)
Pin
Leng
th R
educ
tion
(in.)
AE-5 Tool
AE-6 Tool
AE-7 Tool
AE-8 Tool
AE-9 Tool
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Variable Penetration Tool (VPT)Designed to allow the FS tool to be plunged and retracted while traveling (without use of retractable pin tool)– Weld geometries of varying thicknesses– Eliminates keyhole at end of weld– Robust and simple design
Patent PendingDocket No. 10/970,907
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VPT for FSW of Ti 6-4(VPT) design incorporates tapered pin design – Significantly reduces tool wear and damage– Improves process robustness with greater operating window
Tool material down selected from multi-year study– GE patented, low cost tungsten based alloy with acceptable tool life
(AE-6)
Conventional Tool Design VPT Design
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FSW T-Joint Geometry
T-Joint geometry tooling design and macro– Designed to produce an integral fillet weld on the inside (root)
of the T-Joint geometry
Tooling designed for 0.25-in to 0.5-in thick Ti 6-4 T-joint
Support Tooling
.050-in Chamfer
Ti 6-4
Macro with extruded fillets in root
Ti 6-4
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FSW Corner GeometryCorner joint geometry tooling design and macro– 0.020-in. Ti 6-4 sheet used to ensure penetration without
damaging the tool or backing anvil
Tooling Designed for 0.5-in. to 0.5-in. thick Ti 6-4 corner joint
Support Tooling
.020-in Ti Sheet
Ti 6-4
Macro showing full penetration into 0.020-in. Ti 6-4 Sheet
Ti 6-4
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Ti 6-4 Structural GeometriesButt, Corner and T-Joint example geometries
48-in. Butt Joint
24-in. Corner Joint
60-in. T- Joint
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Stabilizer Arm – Mock Section
FSW XM777 Stabilizer Arm Demonstration Structure
0.188-in. Thick Ti 6-4
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FSW, HLW, GMAW-P Process ComparisonFSWPros– Single pass, full
penetration weld up to 0.5-in
– Completely solid state
– Only basic butt joint fit up required
Cons– Extensive tooling
required– Joint accessibility
limited by machine design
HLWPros– Single pass, full
penetration weld up to 0.5-in
– Lower heat input than GMAW or GTAW
– More gap tolerant that laser only process
Cons– Fit up still an issue– Large # of process
variables
GMAW-PPros– Very adaptable to
most weld geometries
– Off the shelf technology
– Lowest start up cost
Cons– Highest heat input– Multiple passes
required
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Legend
• Friction Stir Welds • Hybrid Laser Welds• GMAW-P Welds
Ti 6-4 Demo Hull Fabrication
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Inner Sidewall to Floor and Inner Sidewall to Angle Plate (FSW)
Ti 6-4 corner joint with non-linear path geometry (0.5-in. to 0.5-in.) Single pass parameters:– 3.5-IPM Travel speed– 150-RPM Spindle speed– 3º Tilt– 0.535-in Penetration
FS Tool Access
60-in.
Tooling model Tooling assembly with welded part
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Sponson to Outer Sidewall T-Joint (FSW)
Ti 6-4 T-joint (0.25-in. to 0.5-in.)Single pass parameters:– 4-IPM Travel speed– 150-RPM Spindle speed– 3º Tilt– .325-in Penetration
Tooling model Tooling assembly with welded part
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Sponson to Lower Sidewall Corner Joint (HLW)
Ti 6-4 corner joint (0.25-in. to 0.5-in.) Single pass parameters:– 17-IPM Travel speed– 215-IPM Wire feed speed
• 0.035-in. wire– 4-kW Laser power
Tooling model Tooling assembly with welded part
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Outer Sidewall to Front Glacis Corner Joint (FSW)
Ti 6-4 corner joint (0.5-in. to 0.5-in.)Single pass parameters:
– 3.5-IPM Travel speed– 150-RPM Spindle speed– 3º Tilt– 0.535-in Penetration
Tooling model Tooling assembly with welded part
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Lower Glacis to Front Glacis Corner Joints (HLW)
Root pass (Laser only)– 20-IPM Travel speed– 4-kW Laser power
Cap pass (HLW)– 15-IPM Travel speed– 215-IPM Wire feed speed
• 0.035-in. wire– 2-kW Laser power
Tooling Model Tooling Assembly with welded part
Ti 6-4 corner joint with multi-step path geometry (0.5-in. to 0.25-in. and 0.5-in.)
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Bulkhead to Front Glacis/OuterSidewall/Sponson/Inner Sidewall (GMAW-P)
Ti 6-4 fillet joint with multi-step path geometry (0.5-in. to 0.25-in. and 0.5-in.)Fillet weld parameters:– 20-IPM Travel speed– 400-IPM Wire feed speed
• 0.045-in. wire
Tooling Model Final Assembly
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Summary
FSW is capable of welding Ti 6-4 structural geometries in a single pass up to ~0.5-in. thick using newly developed tool materials and designsDemmeler tooling allows rapid, highly accurate set-ups with interchangeable partsJoining processes can be combined to create an all welded Ti 6-4 structureNew alternative for machining intensive parts– Weld components to create a near net shape part– Finish machine to print
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