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EuroStir ® Dissemination: Publications, Seminars and Workshops

By: Stephan Kallee [1] (TWI Ltd)

Background

This newsletter article describes how information about friction stir welding (FSW) and the EuroStir ® project was disseminated into the public domain during the period from 1 December 2001 to 31 May 2002 and provides details on two upcoming FSW related events. The EuroStir ® Collaborators have already made significant efforts in publicising this EUREKA programme on 'European Industrialisation of Friction Stir Welding', and so far EuroStir ® has been mentioned in more than thirty-five publications [2-39] . In addition to publications in papers and on the Internet, the EuroStir ® Collaborators have made contributions to friction stir specific meetings, as shown in the notes below:

Structural Integrity Technical Group Meeting at TWI (27 November 2001)

TWI's Structural Integrity Technical Group Meeting on Tuesday 27 November 2001 had the title 'Friction Stir Welds - What are the Properties?' The meeting was hosted by Dr Amin Muhammed (TWI) and chaired by Dr Stephen Webster (Corus). The following contributions were made:

Welcome and Introduction

The chairman, Dr Stephen Webster (Corus), welcomed the attendees to the meeting and gave a brief introduction. He outlined the programme for the day and directed the proceedings for the rest of the day.

Overview and Industrial Applications

Dr Philip Threadgill (TWI) presented an overview of the development of FSW process and current industrial applications. The status of development in different materials was highlighted. This indicated successful applications in aluminium and copper alloys with welding of magnesium, steel, titanium and nickel demonstrated but yet to be fully developed. Dr Threadgill presented the major advantages of FSW and its limitations. Several industrial applications of FSW process in aerospace, rail, marine and automotive sectors were presented. These include the Boeing Delta II fuel tanks (USA), floor and roof panels in high speed trains (Japan), sea and land transport vehicles (Northern Europe). In conclusion, Dr Threadgill stated that FSW is an immature process except for aluminium alloys and that process improvements are expected to continue rapidly.

During the subsequent discussions, the question of detection of defects in FSW was raised. Dr Threadgill stated that root defects in double-sided welds were almost non-existent and that a phased-array system is being developed to address the overall issue of inspection of friction stir welds.

Fatigue Performance and Residual Stresses in Friction Stir Welds

Professor Neil James (Plymouth University) described ongoing work aimed at predicting fatigue properties of single pass (SP) and double pass (DP) friction stir welds. The work involves development of a model for fatigue life prediction of joints in aluminium alloys (5383-H321). Other aspects include the evaluation of travel speed on weld defect population and S-N properties. The work suggests that the main variables affecting fatigue life are residual stresses, microstructure/hardness and presence of small defects. Results of residual stress measurements by hole-drilling, X-ray and synchrotron techniques were presented. The life prediction model and the results of the experimental data are still being evaluated.

Fracture and Fatigue Performance of Friction Stir Welds

Dr Scott Lockyer (TWI) reviewed experimental test data obtained from FSW joints in aluminium and magnesium alloys. The data presented cover tensile, fracture and fatigue properties. The fatigue S-N tests on both defect-free and defect-containing samples were discussed. The main conclusions were that FSW welds have lower tensile strength and hardness but superior fracture/tearing resistance compared to the parent material. Fatigue tests indicate similar fatigue properties to parent material provided there are no large defects present.

During discussions after the presentation, Dr Steve Webster stated that the QualiStir TM European project is investigating non-destructive inspection methods for friction stir welds.

Mechanical and Toughness Properties of Robotic-FSW Repair Welds in 6061-T6 Aluminium Alloys

Alexander von Strombeck (GKSS) presented work on the properties of robotic-FSW repair welds in aluminium alloys. He explained that the work was carried out because the ability to repair welds successfully is crucial for the industrial application of FSW welds. The work scope described included development of repair welding procedure and characterisation of the repair welds. The results presented show that repair welding does not adversely affect properties of FSW welds and the available robotic machines can carry out the repairs.

Stress Corrosion Cracking Properties of Friction Stir Welds

Dr Andrew Leonard (TWI) reviewed the corrosion properties of FSW welds. Work on stress corrosion cracking (SCC), intergranular and exfoliation corrosion resistance of aluminium alloys 2014A-T651 and 7075-T651 were presented. These showed that friction stir welds in 2014A-T651 alloy are not susceptible to SCC or intergranular corrosion. In addition the 2014-T651 FSW nugget was resistant to exfoliation but the parent material and HAZ were susceptible. Friction stir welds in alloy 7075-T651, in the naturally aged condition, were susceptible to both SCC and intergranular corrosion. However, post-weld heat treatment did improve resistance to both SCC and intergranular corrosion, but this was at the expense of resistance to exfoliation. Dr Leonard ended with a caution not to ignore corrosion resistance considerations in the application of FSW.

Residual Stress Effect on Fatigue Crack Propagation in Friction Stir Welds

Dr Claudio Dalle Donne (DLR German Aerospace Center) presented work on the effect of residual stresses on fatigue crack growth rates in friction stir welds. He described how simplistic analyses of test data obtained at low stress ratios indicate better fatigue properties in the FSW welds than the parent material if the effect of residual stresses is not considered. The cut compliance technique for residual stress measurement was described and the presentation showed that FSW crack growth rates fall within the scatter band of parent material data when using the effective crack driving force, which allows for the residual stress. The work also showed that longitudinal residual stresses follow a double-peak profile and are higher in magnitude than transverse residual stresses in friction stir welds.

Fusion Welding of High Strength Aluminium Alloys - An Alternative to Friction Stir Welding

Dr Andy Norman (previously UMIST, now Corus) gave the final presentation of the day on the subject of fusion welding as an alternative to friction stir welding. He described a research project involving several industrial partners aimed at introducing fusion welding into the manufacture of airframes and aero-engines. The presentation described how recent advances with fusion welding have solved much of the earlier problem of solidification cracking while poor mechanical properties (almost zero ductility) remains a problem. Work carried out to improve weldability by developing novel aluminium-scandium (Al-Sc) filler wires was described. The case study presented showed marked improvement in mechanical properties and looks very promising.

Closing Remarks and Future Meeting

The chairman, Dr Stephen Webster (Corus), thanked the speakers and all attendees before bringing the meeting to a close. The next meeting of the technical group is likely to be in November 2002 [40] .

Second GKSS Workshop on Friction Stir Welding (22-23 January 2002)

EuroStir booth with poster and specimen display at the 2nd GKSS Workshop on Friction Stir Welding

Fig.1. The EuroStir ® booth with poster and specimen display at the 2nd GKSS Workshop on Friction Stir Welding © 2001, GKSS
On 22 and 23 January 2002 the 'Second GKSS Workshop on Friction Stir Welding' was held at GKSS. Six papers were presented by EuroStir ® Collaborators and five papers by other investigators or users of the FSW process.

The workshop culminated in the Official Opening of the new 'RIFTEC - Robotic Friction Welding Application and Technology Centre' by GKSS's Scientific Director, Prof Dr Günter von Sengbusch, followed by FSW demonstrations of the Neos Tricept robots and a Comau articulated arm robot.

At the 1 st GKSS/TWI Workshop in May 1999 a general introduction to the FSW process had been given, and this 2 nd GKSS Workshop concentrated on providing an up-date on the state of the art as well as presenting and discussing the potential for FSW applications. The workshop was held in German and mainly attended by industry representatives, who are already working with FSW or who want to work with the process in future.

In the foyer of the GKSS conference centre, a poster exhibition was held and friction stir welding specimens were presented. The EuroStir ® collaborators had a stand with 3 posters and showed specimens that had been produced prior to the event ( Fig.1).

The following paragraphs show notes and abstracts of the papers presented. German Proceedings of the workshop are available at GKSS. [41,42]

FSW - Process and State of the Art [43]

Dr Jorge dos Santos (GKSS) said that FSW was currently being developed all over the world in an interdisciplinary manner. He explained that TWI had licensed 67 organisations to use the patented process. These are industrial companies, research institutes and universities. He presented also Japanese graphs with the number of patent applications and publications, which demonstrated the rapid development of this process. On friction stir welding GKSS concentrate currently on the following R & D activities:
  • Lightweight structures for transport and energy technologies
  • Tool and process development
  • Characterisation and assessment of joints
  • Application of robots

FSW - Invention, Innovations and Applications [44]

Stephan Kallee (TWI) showed a videotape of FSW with a Skew-stir TM motion, where the tool probe conducts an orbital motion. When he described the newest tool developments at TWI, he recommended using the terminology 'probe' instead of 'pin', as this more generic term includes for example, truncated cones, non-round cross sections, conical spirals and whisks. He explained the use of rollers in front or beside the FSW tool and the more sophisticated methods of computerised force or displacement control. Finally he showed applications of FSW at TWI's licensees Airbus UK, Boeing, DanStir, DLR, Hitachi Cable, Laser Tool, NASA, PDC Teknik, Sapa, Simmons Wheels, Tower Automotive and Friction Stir Link and photographs of FSW machines of Crawford-Swift, ESAB, MTS, Hitachi, MCE Technologies, General Tool Company, Tos Kurim and Neos Robotics. Stephan Kallee summarised the following:
  • Friction stir welding is being exploited in the shipbuilding, automotive and rolling stock sectors to produce panels from 6000 and 5000 series aluminium extrusions.
  • The aerospace industry is applying friction stir welding successfully for the series production of spacecraft, made from high-strength aluminium alloys and is investigating its application for civil and military aircraft.
  • FSW can also be used for copper, lead, magnesium, zinc and titanium alloys, as well as for steel and stainless steel.
  • The experiments with Whorl TM, Triflute TM, MultiStage TM, and Skew-stir TM tools have produced promising results and proved that the FSW process can be applied for joining 1-50mm thick aluminium plates in one pass.
  • A total of 33 companies has teamed up in the EuroStir ® project, to get friction stir welding out of the laboratories and into the industrial manufacturing workshops.

Lightweight Structures in Aluminium - Use of FSW near to Production [61]

Bernd Fausten (WKW Erbslöh Automotive GmbH) presented results of dynamic testing of friction stir and laser welds. These demonstrated clearly the benefits of FSW. He said it was fascinating how simple the process appears to be, because of the following reasons:
  • Small number of parameters
  • No noise
  • No fume
  • No radiation

However, he concluded that the FSW process appears initially not suitable for series production, as it is 5 to 6 times slower than laser welding. Several FSW heads could, however, work simultaneously to achieve competitive cycle times. Robots are not necessary for producing straight welds, and only a sufficiently dimensioned linear actuator is needed.

Orbital FSW of Aluminium Pipelines [62]

Siemens gas insulated power transmission line

Fig.2. Siemens gas insulated power transmission line. 1 = enclosure; 2 = inner conductor; 3 = conical insulator; 4 = support insulator; 5 = sliding plug and jack contacts © 2001, Framatome ANP
Gerhard Engelhard (Framatome ANP) reported about a project that was conducted in collaboration with Siemens PTD. In this project the orbital FSW technique was developed for the site assembly of gas insulated power transmission lines (GIL, Fig.2). These are used for transferring high electrical currents under ground.

In the Framatome/Siemens project the following steps were conducted:

  • Feasibility and parameter development studies for circumferential welds at TWI
  • Development and testing of an Orbital FSW System ( Fig.3 and 4)
  • Dealing with pipe tolerances
  • Backing ring and tooling
  • Closing the keyhole at the end of the weld by taper plug welding and ball end plug welding at TWI
  • Non-destructive testing, metallographic investigation and mechanical testing
  • Procedure qualification by TÜV according to AD Specification HP 2/1, DIN EN 288-4
  • Process comparison between orbital TIG and orbital FSW


Welding head of Framatome's orbital FSW machine for pipelines Framatome's orbital FSW machine for welding pipelines under site conditions

Fig.3. Welding head of Framatome's orbital
FSW machine for pipelines © 2001, Framatome ANP

Fig.4. Framatome's orbital FSW machine for welding pipelines
under site conditions © 2001, Framatome ANP

FSW in Production using ESAB SuperStir TM Plants [63]

Esab SuperStir machine for weldinghousings for electrical motors

Fig.5. ESAB SuperStir TM machine for welding housings for electrical motors at Hydro Aluminium in Magnor (Norway) © 2001, ESAB
Principle of the FSSW device and of the RIFTEC Bobbin tool

Fig.6. Principle of the FSSW device and of the RIFTEC Bobbin tool © 2001, GKSS
Stefan Stoltz (ESAB) explained the SuperStir TM machines that have been installed in production and laboratory environments ( Fig.5). The concepts are as follows:
  • Moving C frame
  • Hinged or traversing boom
  • Gantry
  • Moving table with stationary head
  • Single, double and triple head machines
  • Carousel or revolver like workpiece manipulators

It was presented orally that when welding from two sides simultaneously, up to 6m/min welding speeds could be achieved in 6mm thick aluminium extrusions.

Friction Stir Spot Welding (FSSW) [64]

Christoph Schilling (GKSS) reported about a study on friction stir spot welding (FSSW). For this study a tool, which had been developed especially for lap joints, was attached to a Comau articulated arm robot ( Fig.6). FSSW joints with seam lengths equivalent to 6mm, 7mm, and 10mm diameter resistance spot welds were produced in aluminium alloy 6061-T4. Sheets with thicknesses from 1 to 3mm were joined to 3mm thick sheets in 10 different configurations. The results obtained in shear tests describe a similar pattern to those reported in the literature for resistance spot welds. For FSSW the threshold thickness between shear and pullout failure varied between 1 and 2mm for spot diameters ranging from 6 to 10mm. In summary, the static and fatigue properties were reported to be better than those known from resistance seam welds.

Robotic FSW [65]

Alexander von Strombeck (GKSS) reported on robotic friction stir welding. He summarised that the following benefits can be achieved, when using robots for FSW:
  • Increased scope of applications of FSW
  • Flexible use of FSW through a system that is easy to operate and integrate
  • Integration of FSW to complex manufacturing sequences involving further operations such as machining or drilling
  • Application of FSW to industrial components with complex joint geometries

He published a new concept for close-loop-control with the Neos Tricept 805 robot. The CNC system of this model is different to that of previous models and a sixth axis with load sensors and actuators seems necessary to achieve fast response times.

He reported that in a GKSS project a small series of 5 prototype lorry tanks has been welded using the Neos Tricept 805 robot. These tanks are now being tested in a systematic study.

Friction Stir Welding from the Perspective of a User in the Rail Car Production [66]

Oliver Blach (Alstom LHB) reported about introducing the FSW process to Alstom LHB. Since 1997 their company uses prefabricated aluminium panels for roofs of the Copenhagen suburb trains. These FSW panels are purchased from a commercial supplier. In March 1999, TWI presented the benefits of the FSW process to Alstom LHB engineers. They considered at this time applying the process in-house for manufacturing floor and side panels from hollow aluminium profiles, but estimated that the capital investment for a suitable facility would be in the order of approximately euro3.5M. A three-shift operation would therefore be necessary for an economic time schedule for return on investment.

They estimate that the most significant technical and economic benefits could be achieved when applying FSW to aluminium joints with more than 12mm thickness. This would replace mechanised MIG welding and the combined activities of pre-heating and grinding of intermediate beads. Additionally, it would lead to improved quality of the welds. Therefore, the main longitudinal member of the Munich suburb trains BR423 was selected as a demonstrator part.

In August 1999 the first pilot trials were made with a converted milling tool. An R & D contract was then given to SLV Berlin-Brandenburg for developing the following:

  • FSW tools (geometry and material)
  • Welding parameters (rotation speed, welding speed and tilt angle)
  • Geometry of the aluminium extrusions (joints, effect of the joining forces applied)

In July 2000 experiments with innovative FSW tools were conducted on a 5-axis milling machine. These experiments were very successful, but sometimes difficult to reproduce. Occasionally, internal voids were generated, as known from applying an insufficient tool heel plunge depth. This lack of reproducibility was caused by overloading the milling machine. The axial spindle forces of up to 30kN (3t) resulted in a significantly reduced lifetime of the spindle bearings, and in January 2001 the spindle and tilting head needed to be refurbished.

If a tool normal to the workpiece surface was used, an existing heavy-duty vertical boring mill could be used without the need for a tilting mechanism. In June 2001, Alstom LHB decided therefore to develop a 0° FSW tool and placed a contract with EADS in Ottobrunn near Munich for the necessary development studies. Initially, a weld with a 13mm long pin was made in 30mm plates of AA6082.

Now they are making design changes to the ribs of the hollow extrusions and intend to produce a series of pre-production prototypes for qualification according to DIN EN 6700. The series production is scheduled to start in the second half of 2002. A governmentally funded R & D project has been proposed for obtaining design values for FSW joints in collaboration with TU Clausthal and SLV Berlin-Brandenburg. Additionally, there is a need for non-destructive testing (NDT).

FSW in the Aircraft Manufacture [67]

Daniela Lohwasser (Airbus Deutschland) reported that there was an interest in using friction stir welding for the fuselage of aircraft (especially for longitudinal and circumferential welds). The process is also being developed further for the application to the wings. The European aeronautical industry is conducting collaborative projects to confirm the potential of this welding process for the manufacture of structural parts. For the qualification of this process a number of studies is necessary. All coupon tests conducted so far show very good results, so that now full-size demonstration parts are being produced at TWI for the TANGO programme.

Interaction of Material Flow and Joint Formation as well as Weld Properties during FSW of Al Materials [68]

Frank Palm (EADS Forschung) reported about generic research activities on an improved process understanding. He showed metallographic sections to explain the material flow during FSW. He defined the following FSW parameter:
  • Theta = rotation speed/welding speed

Frank Palm warned about insufficient bonding at a combination of low rotation speeds and high welding speeds. When developing FSW parameters, he recommended not to focus too much on the welding speed but on process reliability. He also mentioned the importance of the Kahn Tear Test according to ASTM B 871-96, which gives values for the Tear Strength and Unit Propagation Energy.

Investigation on FSW of Al Alloys for Application in the Automotive Industry [69]

Matthias Nüchtern (Wagon Automotive) reported that GKSS had investigated robotic friction stir welding of several combinations of aluminium alloys as follows:
  • Sheet AA5754 to sheet AA5754 (i.e. AlMg3)
  • Sheet AA5754 to pressure die cast AA/ASTM A360 (i.e. GD AlSi10Mg)
  • Sheet AA5754 to extrusion AA6060 (i.e. AlMgSi0.5)
  • Pressure die cast AA/ASTM A360 to extrusion AA6060

A standard tool (flat shoulder ø13mm, pin ø5mm) was compared with a tool that had been optimised for welding concave and convex joint lines (concave shoulder ø10mm, pin ø4mm). The former tool could weld gaps of up to 40% of the 2mm thick sheets, and the latter tool could weld gaps of up to 15% of the 2mm thick sheets. Two gaps of 60mm length had been machined into the 150mm long samples.

Phased Arrays for the Evaluation of Friction Stir Welds [70]

Lutz Lindecke (RD Tech) presented the innovative phased array technique [71] , which is currently being investigated in the QualiStir TM project, in which RD Tech, TWI and GKSS are main partners. He reported on a study in which an 8m long weld had to be fully inspected within 1 hour. The defects may be axial or transverse with unpredictable orientations. The following defects were supplied:
  • Eight EDM notches on root and crown (electro discharge machined)
  • Flaw in centre line
  • Tight crack undetected by ultrasonic testing (UT)
  • Tight 0.4mm (0.015") flaw at the root
  • Crack in crown at the centre of the weld (axial and oblique)
  • Crack in root away from weld (transverse)
  • Crack in crown away from weld (transverse)
  • Crack in root at centre of the weld (axial)
  • Crack in root at centre of the weld (transverse)

The RD Tech phased array system can be calibrated by applying it to EDM notches of a given depth (e.g. 0.125; 0.25; 0.5 and 1.0mm). Figures of the RD Tech display were shown at the workshop and are reproduced in the proceedings. The following conclusions can be drawn:

  • An RD Tech "Focus 16/64" phased array system detected all defects present
  • Due to FSW lips, immersion in a water chamber is required
  • Probability of detection is maximised by electronic scanning at several angles
  • Transverse defects can be detected by lateral scanning
  • Phased arrays can scan at 20kHz, which is much faster than mechanical scanning
  • Electronic scanning can compensate for position errors from the delivery system
  • Phased arrays eliminate the need for a second scanning axis

FSW in the Shipbuilding Industry [72]

Ole Terje Midling (Hydro Marine Aluminium) gave an impressive overview of the success they have with the series production of FSW panels using their 16m long and 16m wide ESAB SuperStir TM system in Haugesund, Norway. This was the first machine that had been purpose built for FSW in 1996. So far 285km of welds have been produced for marine applications. Part of the success is the use of accurately manufactured aluminium extrusions, which have 9 tolerance demands. They are ideally used 1-2 days after T6 heat treatment (artificial ageing). The reproducibility is so high that X-ray inspection can be omitted in future in accordance with revised procedures of the classification societies. Radiography will be replaced by other means of non-destructive testing. The following ships contain friction stir welded panels or subassemblies produced by Hydro Marine Aluminium:
  • Silver Whisper
  • Seven Seas Navigator
  • The World
  • Finnmarken
  • P & O Golden Princess by Fincantieri (15m long balconies)
  • Oseberg Sør

Future R & D Needs during FSW

Dr Jorge dos Santos (GKSS) and Karl-Heinz Lindner (WKW Erbslöh Automotive) moderated a discussion session, which concluded the second GKSS FSW Workshop. The following R & D topics were listed by the attendees:
  • Fatigue properties
  • True lightweight construction
  • Coatings of the FSW tools
  • Surface contamination of the workpieces
  • Modelling
  • Tolerances
  • FSW specific design
  • Cost factors and models

First Railway Industry Friction Stir Welding Meeting (11 April 2002)

TWI hosted the 1 st Railway Industry Friction Stir Welding meeting on 11 April 2002 at TWI to discuss the benefits of friction stir welding of railcars ( Fig.7-10).

This meeting was held as a consequence of one of Lord Cullen's recommendations of the inquiry of the Ladbroke Grove [73] rail accident. In the invitation to this meeting it was mentioned that experts advising Lord Cullen on crashworthiness agreed that consideration should be given to 'the use of alternatives to fusion welding' [74] . Friction stir welding is a strong candidate welding process.

First Railway Industry Friction Stir Welding Meeting at TWI Tasks of R and D projects and overlap between them

Fig.7. First Railway Industry Friction Stir Welding Meeting at TWI © 2002, TWI Ltd

Fig.8. Tasks of R & D projects and overlap between them © 2002, TWI Ltd


First EuroStir Railway Industry Friction Stir Welding Meeting at TWI Brainstorming session to determine the research needs

Fig.9. First EuroStir ® Railway Industry Friction Stir Welding Meeting at TWI © 2002, TWI Ltd

Fig.10. Brainstorming session to determine the research needs during First EuroStir ® Railway Industry Friction Stir Welding Meeting at TWI © 2002, TWI Ltd

Friction stir welding is already widely used in the rail sector in Japan, where the combination of good mechanical properties, low distortion and competitive cost have been recognised.

Railway Safety and Angel Trains, who are now sponsoring EuroStir ® work at TWI, and HSBC Rail (UK) requested that TWI arrange the workshop so that their work programme best supports the introduction of FSW within the rail industry. The workshop was chaired by Railway Safety. Representatives of the following organisations were invited:

  • Alstom Transport
  • Angel Trains
  • ATOC
  • Bombardier Transportation
  • DanStir
  • HSBC Rail (UK)
  • Porterbrook Leasing
  • Railway Safety
  • TWI

The slides of the presentations are shown on www.eurostir.co.uk and the agenda was as follows:

The minutes [81] with the output from this meeting are accessible on www.eurostir.co.uk. Some of the key issues that emerged can be summarised as follows:

  • Requirements for safer, crashworthy joint construction.
  • Economics.
  • Potential process problems and means of inspection.
  • Possible effect of heat/fire in service and repairability.
  • Comparison of friction stir and MIG welds regarding dynamic impact performance (including assessment of aluminium structures that failed in the heat affected zones near welds - this is often described as 'unzipping').
  • Fatigue and ductility.
  • Development of 'standard' tests, which allow comparisons between joint options.
  • Joint design options should include both materials and configuration.
  • Full scale crash testing is needed as well as modelling techniques to link full-scale and small-scale performance.

Plans for Future Workshops/Seminars

As part of the EuroStir ® dissemination a number of workshops/seminars will be held, and EuroStir ® collaborators will also give presentations at other FSW related conferences and symposia. The dates and venues for EuroStir ® workshops / seminars will be published on www.eurostir.co.uk. TWI will provide essential assistance at all seminars and workshops. However, TWI will also encourage all Collaborators to contribute and attendees to help with the administration costs by paying a small attendance fee. The following events are being planned:

EuroStir ® Workshop at TWI will Bring Friction Stir Welding to Industry (16 July 2002)

A workshop with the title 'Friction stir welding - making it work for you' covering the benefits of using this process in industrial applications is to be held on Tuesday, 16 July 2002 at TWI Ltd, Cambridge, UK [82]

It offers a rare opportunity to hear presentations from experts in the field and see live demonstrations of friction stir welding. This is the first 'hands-on' workshop to be held under the EUREKA EuroStir ® programme.

The workshop will provide details of the process and equipment that will be useful to both present users and newcomers to the technology. The 'show and tell' approach will illustrate the strong economic advantages of the process and demonstrate to management and technical personnel alike the benefits of applying friction stir technology.

The workshop offers a chance to get to grips with this ground-breaking technology and be guided by experts in the field. Attendance is forecast to be high so early enrolment is advised [83] . The workshop is provided on a cost only basis with existing project collaborators donating their efforts free of charge. The programme will be as follows:

  • Welcome to TWI - Dr Richard Dolby, Director, Research & Technology, TWI
  • The EuroStir ® Project - Dr Stephen Webster, Corus
  • Role of the DTI - Phil Barham, Innovation Group, Department of Trade & Industry
  • FSW Process Fundamentals - Dave Nicholas, Business/Technology Development Manager, Friction & Forge Processes, TWI
  • Equipment for FSW - Jonathan Martin, Technical Director, Smart Technology Group - Crawford Swift
  • Current and Potential FSW Applications - Stephan Kallee, Collaborative Project Manager, Friction and Forge Welding Processes, TWI
  • FSW Comparative Process Economics - Mike Turner, Consultant, Promweld Ltd
  • Practical Demonstrations

Fourth International Symposium on Friction Stir Welding (14-16 May 2003)

The Friction Stir Welding Licensees Association is pleased to announce that the 4 th Symposium in the series will be held on 14-16 May 2003 in Park City, Utah, USA

The International Friction Stir Welding Symposia are now established as the leading forum for exchange of ideas and information in this area. The 4 th Symposium will be open to all persons with an interest in friction stir welding. The meeting will be hosted by Brigham Young University. Topics will include:

  • Improvements in process technology
  • Friction stir welding of new materials
  • Improvements in modelling and theory
  • Microstructural and mechanical properties
  • Design with friction stir welding
  • Quality control and production issues
  • New industrial applications
  • Corrosion studies

The Symposium will be held in conjunction with the 5 th meeting of the FSW Licensees Association (a separate meeting which is open to FSW licence holders only) which will be held on 14 May 2003.

All EuroStir ® collaborators are being encouraged to provide abstracts, which summarise high quality and innovative FSW research and development, or which describe new FSW applications. Informative abstracts (½ page max.) should be submitted to FSW Symposium Administrator, Diana Fairmaner (TWI) [84] by 30 September 2002. Completed papers will be required by 31 January 2003 and will be distributed prior to the symposium in CD format. Detailed instructions on page layout will be sent to the authors.

Links and references

1.   stephan.kallee@twi.co.uk

2.   Nicholas E D, Kallee S W and Brózda J: 'Zgrezwanie tarciowe z mieszaniem materialu zgrzeiny - 10 lat od wynalezienia procesu'. Seminar Nowosci w technologii oraz w urzadzeniach do zgrzewania metalli, Institut Spawalnictwa, Gliwice, 24 January 2001.

3.   Scherer M: 'Nouveau départ pour la friction'. Industries and Techniques, No 824, March 2001, pp. 66-67.

4.   Nicholas E D, Kallee S W and Brózda J: 'Proces zgrzewania arciowego z mieszaniem materialu zgrzeiny ma juz 10 lat'. Bulletyn 3/2001 (45) pp. 30-37.

5.   Anon: 'Causing a stir in the House of Commons'. Welding & Metal Fabrication, May 2001 69 (4) p. 2.

6.   Kallee S W: 'Welding contract causes a stir'. Metal Bulletin Monthly, May 2001 (365) p. 57.

7.   Kallee S W and Dyson H B: 'Giant contract causes a stir in Parliament'. TWI Connect May/June 2001 (112) p. 1.

8.   Kallee S W: 'Vertrag zur Förderung des Rührreibschweißens'. Schweissen & Schneiden, 6/2001, p. 332.

9.   Anon: 'An international agreement [...] has been signed'. Welding and Cutting 0/2001, p. 11 and www.dvs-verlag.de/en/wac/NEWS_Automation_specialist.pdf

10.  Anon: 'Prozesskette AFS (Aluminium Schaum Sandwich) - Stand der Wissenschaft und Technik'. www.prozesskette-afs.de/stand.html

11.  Anon: 'Continued success for ESAB SuperStir TM'. Svetsaren 2001 56 (1) p. 15. www.esab.com/Templates/T005.asp?id=36618

12.  www.weldnet.com.cn/chinese/kuixun/kuaixun16.htm CWA-WI-CMES Welding Newsletter, in Chinese, 15 June 2001.

13.  Strombeck A von, Schilling C, Santos J F dos: 'Zrobotyzowane zgrzewanie tarciowe z mieszaniem materialu zgrzeiny - narzedzie, technologia I zastosowanie'. Bulletyn 6/2001 (45) pp. 49-57.

14.  Eriksson L G and Larsson R: 'Friction stir welding - new technology changing the rules of the game in Al construction'. Svetsaren No 2-3, 2001, pp. 3-6.

15.  Kallee S W, Nicholas E D and Thomas W M: 'Friction stir welding - invention, innovations and applications'. 8 th Incalco International Conference on Joints in Aluminium, Munich, Germany, 28-30 March 2001, pp. 1-1-1 to 1-1-13.

16.  Dadson J R and Smith B J: 'News from TWI', Contact Video, 28, Summer 2001.

17.  Kallee S W, Nicholas E D and Thomas W M: 'Friction stir welding - invention, innovations and applications'. Tube International, July/August 2001, pp 246-250.

18.  Kallee S W: 'The world's largest Laboratory friction stir machine installed at TWI', Connect Sept/Oct 2001, p. 2.

19.  Anon: 'Friction Stir Welding'. In Japanese. www.s-iri.pref.shizuoka.jp/tech/mach/me131032.htm

20.  Anon: 'Largest FSW installation'. Aluminium Today, Oct/Nov 2001, p. 6.

21.  Kallee S W: 'Industry exploits TWI services at Essen'. Connect Nov/Dec 2001. www.twi.co.uk/content/c1157a.html

22.  Davenport J, Kallee S W and Wylde J G: 'Europe follows Japan into friction stir welding'. Railway Gazette International, November 2001, pp. 777-780.

23.  Kallee S W: 'Industry exploits TWI services at Essen'. Connect Nov/Dec 2001, p. 7.

24.  Boucher C: 'Le procédé friction stir welding aspects techniques'. Euroforum on Acier, aluminium, magnesium, alliages legers, ...: quells choix pour quelles applications? Saint James & Albany, 5-6 Dec 2001.

25.  Kallee S W, Nicholas E D and Thomas W M: 'Industrialisation of friction stir welding for aerospace structures'. Third European Conference on Structures and Technologies - Challenges for Future Launchers, Strasbourg 11-14 December 2001. www.twi.co.uk/content/spswkdec2001.html

26.  Vortisch M: 'Vacuum clamping technology for friction stir welding'. Witte Info, December 2001.

27.  Santos J F dos, Strombeck A von and Schilling C: 'Reibrührschweißen - Verfahren und Stand der Technik'. 2nd GKSS Workshop Reibrührschweißen, GKSS Forschungszentrum, Geesthacht, Germany. 22-23 January 2002, p. 6.

28.  Antonsson S: ' Friction stir welding in Denmark'. Svetsaren 2002 57 (1) p17. www.esab.com/ESABHtml/pdf/Svetsaren1-02.pdf

29.  Kallee S W, Nicholas E D and Thomas W M: 'Reibrührschweißen: Erfindung, Innovationen und Anwendungen - Friction Stir Welding: Invention, Innovations and Applications'. 2 nd GKSS Workshop Reibrührschweißen, GKSS Forschungszentrum, Geesthacht, Germany. 22-23 Jan 2002.

30.  Rasmussen J F: 'Første danske virksomhed med speciale i Friction Stir Welding.' Dansk Teknisk, February 2002.

31.  Wraige H: 'A weld of opportunity'. Professional Engineering, 13 February 2002, pp. 37-38.

32.  Anon: 'Steeled for the future'. Eureka Bulletin, Issue 16, 2002, p 5. www.eureka.be/ifs/files/public/Eureka/Members/United%20Kingdom/HomePage/eurekaBulletin_issue16.pdf (90 sec)

33.  Anon: 'RIFTEC - Joint research upon friction stir welding'. SMT Tricept Times 2002, p 11.

34.  Kallee S W, Nicholas E D and Thomas W M: 'Reibrührschweißen: Erfindung, Innovationen und Industrialisierung - Friction Stir Welding: Invention, Innovations and Industrialisation.'Seminar "Rührreibschweißen (FSW) - ein modernes Fügever-fah-ren", Schweißtechnische Lehr- und Versuchsanstalt (SLV) Berlin-Brandenburg, 20 Mar 2002, www.slv-bb.de/seminare/semi13.html

35.  Woodroffe G: 'Railway Safety - Research Programme - Summary of Current Research - March 2002'. www.railwaysafety.org.uk/pdf/rscr_mar.pdf

36.  Lorentzen T: 'First dedicated friction stir welding job shop in Denmark'. Connect Mar/Apr 2002, p 3, www.twi.co.uk/content/c1173.html

37.  Kallee S W: 'EuroStir ® - EUREKA supported: European industrialisation of friction stir welding.' Workshop on Research in Welding for Aerospace and Related Sectors: Current Programme Update. DTI Conf Centre, London, 26 April 2002.

38.  Anon: 'Workshop brings friction stir welding to industry's attention'. Engineering Capacity, May 2002, p 11.

39.  Ussing S: 'Projekter: SASAK og EuroStir'. Letmetaldagen, Odense, Denmark, 15 May 2002, www.atv-semapp.dk/ARR2002/020515Letmetaldagen/020515_Letmetal_update0408.htm and http://www.atv-semapp.dk/ARR2002/020515Letmetaldagen/letmetaldag_program.pdf

40.  Further information on TWI's next Structural Integrity Group Meeting can be obtained from amin.muhammed@twi.co.uk

41.  Santos J F dos, Strombeck A von and Schilling C: "Reibrührschweißen (Friction Stir Welding)". 2 nd GKSS Workshop. 22-23 January 2002, GKSS Forschungszentrum Geesthacht, Germany. Proceeding available at alexander.von.strombeck@gkss.de

42.  Summary to be published at www.eurostir.co.uk

43.  Santos J F dos, Strombeck A von and Schilling C (GKSS Forschungszentrum, Geesthacht, Germany): 'Reibrührschweißen - Verfahren und Stand der Technik'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

44.  Kallee S W, Nicholas E D and Thomas W M (TWI Ltd, Great Abington, UK): 'Reibrührschweißen: Erfindung, Innovationen und Anwendungen' 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

45.  www.boeing.com/companyoffices/gallery/images/space/delta_iv/d4_mfg_06.htm and www.boeing.com/companyoffices/gallery/images/space/delta_iv/d4_mfg_03.htm

46.  www.danstir.dk/superstir.htm

47.  www.kp.dlr.de/WB-WF/e_lagun.htm

48.  www2.hitachi-cable.co.jp/apps/hnews.nsf/e9221cf9ff0d399d4925646e002f3120/22ef775c6fa328fd49256a320033f86f?OpenDocument

49.  www.fredrick.com/solidedge/fame.html

50.  www.railway-technology.com/contractors/training/sapa/sapa3.html

51.  www.simmonswheel.com.au/technical.html#rim and www.jdwheels.com/images/simmons%20fr.jpg

52.  www.towerautomotive.com/03_04_02.htm and www.towerautomotive.com/03_02_03.htm

53.  www.frictionstirlink.com/s_what.htm

54.  www.crawfordswift.co.uk/newpage1.htm

55.  europe.esab.net/ESABHtml/pdf/svetsaren/Svetsaren%202-3_01%20ENG.pdf pp.3-6

56.  www.mts.com/aesd/friction_stir1.htm

57.  www.mcetechnologies.com/stirnich.htm

58.  www.gentool.com/pages/fabrication.html

59.  www.tos-kurim.cz/tos/en/vprog.htm and www.tos-kurim.cz/tos/en/ref.htm

60.  195.67.110.7/neos/pages/pg5-2_eng.htm

61.  Fausten B and Lindner K-H (WKW Erbslöh Automotive GmbH, Velbert, Germany): 'Leichtbau aus Aluminium - Produktionsnaher Einsatz des FSW Verfahrens'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

62.  Engelhard G (Framatome ANP, Erlangen, Germany) and Hillers T (Siemens AG, PTD, Erlangen, Germany): 'Orbital Reibrührschweißen von Aluminiumrohren'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

63.  Stoltz S, Larsson R, Antonsson S and Söderberg P (ESAB, Låxa, Sweden): 'Rührreibschweißen in Produktion mit ESAB SuperStir TM Anlagen'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

64.  Schilling C, Santos J F dos and Strombeck A von (GKSS Forschungszentrum, Germany): 'FSW Punktschweißen'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

65.  Strombeck A von, Schilling C and Santos J F dos (GKSS Forschungszentrum, Geesthacht, Germany): 'Robotic FSW'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

66.  Blach O and Senne F (Alstom LHB GmbH, Salzgitter, Germany): 'Reibrührschweißen aus der Sicht eines Anwenders im Schienenfahrzeugbau'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

67.  Lohwasser D (Airbus Deutschland GmbH, Bremen, Germany): 'FSW im Flugzeugbau'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

68.  Palm F (EADS-CRC, Ottobrunn, Germany): 'Wechselwirkungen zwischen Materialfluß und Verbindungsbildung sowie Nahteigenschaften während des Reibrührschweißens von Al- Legierungen'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

69.  Nüchtern M and Stapp A (Wagon Automotive GmbH, Waldaschaff, Germany): 'Untersuchung des Reibrührschweißens von Al-Legierungen im Hinblick auf Anwendungen im Automobilbau'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

70.  Lindecke L (RD Tech, Caputh, Germany): 'Zerstörungsfreie Prüfung von FSW Verbindungen'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

71.  Lamarre A and Moles M: 'Ultrasound phased array inspection technology for the evaluation of friction stir welds'. 15 th World Conf on Non-destructive Testing, Rome, Italy, 15-21 Oct 2000, www.ndt.net/article/wcndt00/papers/idn513/idn513.htm

72.  Midling O T (Hydro Marine Aluminium, Haugesund, Norway): 'Reibrührschweißen im Schiffbau'. 2 nd GKSS Workshop, 22-23 Jan 2002, GKSS, Geesthacht, Germany.

73.  www.lgri.org.uk

74.  www.hse.gov.uk/railway/paddrail/lgri1.pdf see Chapter 13.9, page 197 of the book, page 206 of the *.pdf file.

75.  www.eurostir.co.uk/eurostir_railway11042002_02.pdf

76.  www.eurostir.co.uk/eurostir_railway11042002_03.pdf

77.  www.eurostir.co.uk/eurostir_railway11042002_04.pdf

78.  www.eurostir.co.uk/eurostir_railway11042002_05.pdf

79.  www.eurostir.co.uk/eurostir_railway11042002_06.pdf

80.  www.eurostir.co.uk/eurostir_railway11042002_07.pdf

81.  www.eurostir.co.uk/eurostir_railway11042002.html

82.  This event was on 16th July 2002

83.  This event took place on 16 July 2002

84.  diana.fairmaner@twi.co.uk Copyright © 2004 TWI Ltd
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