Latest news / events
- Assessment of Bobbin Friction Stir Welding for the Joining of Aluminium Alloys
- High pressure hydrogen testing
- Structural performance of components for racing vehicles
- New certification scheme for welding co-ordinators
- Resistance Welding - Training course
- WJS Branch Events - October
- Composites research fuels innovative application
Assessment of Bobbin Friction Stir Welding for the Joining of Aluminium Alloys
The friction stir welding (FSW) process was invented by TWI and was originally developed for industrial exploitation via a TWI Group Sponsored Project (GSP), the Sponsors of which were amongst the first to benefit from the new technology. TWI has recently developed a novel enhancement to the FSW process, which offers the potential to produce improved full penetration welding performance using significantly simplified, and therefore cheaper, equipment. The enhanced process can be implemented in two varieties named fixed and floating bobbin FSW. Bobbin friction stir welding has the potential to be a valuable high productivity manufacturing technique for structures of interest to the transport industries, offering high quality, highly repeatable welds at a competitive cost. It is proposed to develop, evaluate, and demonstrate the capabilities and benefits of bobbin FSW via a new GSP. Participants in the GSP will be ideally placed to become early adopters of the new technique and to benefit from the enhanced capabilities that it offers.
Launch Meetings - Japan and UK
Japan
Venue: Tokyo-to ChushoKigyo Shinko Kosha (Shokuhin Gijutsu Center)
Tel: 03-3257-0741 at Akihabara.
Date: 17 October 2008
Time: from 13.30hrs
UK
Venue: TWI Ltd Granta Park, Great Abington, Cambridge CB21 6AL
Tel: +44 (0) 223 899000
Date: 21 October 2008
Time: 13.30hrs BST
For further information, please click here.
High pressure hydrogen testing
Commissioning trials nearing completion
TWI's capabilities for high pressure hydrogen testing have recently been extended with the development of a new purpose designed test facility. Commissioning trials are almost complete and it is anticipated that the first research programme carried out for an Industrial Member using the facility will commence in October.
The new facility will be capable of operating at 1000bar, within a temperature range of +85 to -150°C. The equipment is designed for testing in high pressure hydrogen but equally can be used for high pressure testing in other environments. A range of tests can be carried out including fatigue, tensile testing and fracture toughness testing.
The equipment supplements TWI's existing facility which is designed to operate up to 450bar at temperatures from ambient up to 85°C. The first facility was initially designed and built in order to carry out a large programme of tests for the Japan Research and Development Centre which is working closely with the TWI Industrial Member, Nippon Steel Corporation (NSC).
The work was part of a large programme being undertaken in Japan to provide data to support the activities in Japan related to the use of hydrogen as an alternative fuel. In particular, test data are required to ensure the safe performance of hydrogen storage and handling systems for automotive applications and specifically for hydrogen storage tanks for passenger vehicles. Clearly safety issues are paramount and thus the performance of potential materials needs to be thoroughly researched in the appropriate environment.
The two testing facilities are located in an isolated building, which is also scheduled to house an elevated temperature hydrogen autoclave (for disbonding testing and hydrogen charging) which is being re-located on the Abington site. The building has a test booth for each pressure vessel, and a control room separated from the testing machines by steel doors with a safety interlock. The roof over the test booth is of lightweight construction, and would provide an easy path for any sudden pressure release or explosion. The combination of interlocks, gas and fire detectors and procedures, however, make this an extremely unlikely event.
It is anticipated that demand for the two facilities will be high and testing programmes are already planned. Members requiring more information or enquiring about their availability should contact hydrogen@twi.co.uk.
Structural performance of components for racing vehicles
The performance engineering sector of the UK has always been personified by the high performance technologies applied to Formula One motor racing where the structural performance of components is critical to racing success. TWI has been involved with supporting the materials validation, inspection and joining requirements for several race teams over the years, and recently there has been an increase in the volume of R&D support provided to this sector.
One recent example where TWI has provided support is in the application of its advanced electron beam welding technologies. This particular example related to the fabrication of small pressure vessels manufactured from thin wall titanium. The EB process was used to weld two dome ends to these assemblies. The thin walls of the structure and the predicted in-service conditions meant that the highest degree of quality and joint integrity was required.
Due to the range of specialised equipment and staff on hand, TWI was able to provide a specific technical solution for the fabrication of these critical components which were raced on Formula One cars during the 2007 FIA Formula One World Championship.
New certification scheme for welding co-ordinators
For companies to comply with the ISO 3834 certification scheme they must have a suitably qualified Welding Co-ordinator in accordance with ISO 14731 entitled 'Welding Co-ordination Tasks and Responsibilities'.
With the introduction of the new scheme TWI offers a comprehensive service of compliance assessment and certification in accordance with both ISOs 3834 and 14731.
These services bring maximum recognition to customers via UKAS accreditation and IIW/EWF authorisation.
Stage One
TWI Training and Examination Services provide training and examinations to satisfy the requirements of the scheme in accordance with the relevant standards.
Before enrolling on the course, applicants must complete an evaluation process for which a fee will be charged.
The five day course comprises:
Day 1: Module 1 - Welding processes
Day 2: Module 2 - Materials
Day 3: Module 3 - Construction and design
Day 4: Module 4 - Fabrication and application
Day 5: CSWIP examinations on each of the four modules, one paper per module, each with 50 multi-choice questions.
One hour is allowed for each paper covering the applicable modules subjects and two hours is allowed for the case study.
Stage Two
After completion of stage one, candidates may enter stage two which involves a professional interview.
The next available course date is 10 November 2008 at TWI North in Middlesbrough. Fee: £1250 + VAT (inc. CSWIP exam)
For further information, please contact trainexam@twi.co.uk
Resistance Welding - Training course
Tuesday, October 7th 2008
Venue: TWI Head Office (Great Abington, Cambridge, UK)
Course Event Information:
| Duration: | 2.0 day(s) |
| Starting: | 07-OCT-2008 |
| Location: | United Kingdom |
| Venue: | Abington |
| Fees | |
| Course & Examination: | £605.00 + VAT |
Suitable for:
Welding engineers, production engineers, QC personnel, setters, operators and maintenance staff.
Course Content:
Principles of the resistance welding process and equipment; outline of the electrical controls; guidance on the setting-up and control of weld quality; demonstration of the effect of welding parameters, machine characteristics and
material on spot welds in steel sheet; consideration of electrode requirements; welding of high strength and coated steels, aluminium etc; testing, monitoring and NDT; maintenance and safety.
Objectives:
- understand the principles of resistance welding
- appreciate how process parameters and other factors influence quality of resistance welds
- carry out setting up and troubleshooting tasks more effectively
For further information, please contact trainexam@twi.co.uk
WJS Branch Events - October
Engineering at the Cutting Edge
The Hume-Rothery Lecture Theatre, University of Sheffield
Saturday, October 18th 2008
Plasma Welding
The Connaught Hotel, Wolverhampton
Monday, October 20th 2008
Works Visit: Jamun Racing (Formula Ford winning team)
Joint meeting with IMI West (host)
Medway City Estates, Frindsbury
Wednesday, October 22nd 2008
For further information, please contact twi_professional@twi.co.uk
Composites research fuels innovative application
Composites sandwich panels are gaining popularity in industry for a number of reasons, such as good mechanical strength, electrical insulation properties, resistance to corrosion and ease of use. Now there is an additional requirement to add value, as most industry sectors are looking for ways to improve their products by incorporating additional functionality.
TWI has now developed a mechanism (patent applied for) which enables composite sandwich panels to be formed with integral fuel cells thus providing power to structures containing them.
This approach removes many of the drawbacks associated with current methods of combining polymer electrolyte membrane fuel cells (PEMFCs) with laminate or sandwich structures, such as excluding the requirement for complex housing design.
Integrating the PEMFC into a sandwich structure helps prevent the damage or loss of fuel cell functionality when assembling the stack and enables the construction of complex field flow plates to achieve good gas transfer to the electrodes by specific machined channels in the composite laminate.
The initial feasibility study has shown that a very simple single device embedded into a composite can provide power similar to an AA 1.5 volt battery.
TWI has a long history of innovation in joining technology in both the fuel cell and composites fields and is now in need of partners to take this to market.
For more information and to register your interest, please contact Paul Burling. paul.burling@twi.co.uk
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