Second EuroStir ^® Workshop at TWI: 'Friction Stir Welding - an intensive interactive day on the technical and economic benefits' (6 Nov 2002)

By: Stephan Kallee (TWI Ltd)

The second EuroStir ^® Workshop, held at TWI on 6 November 2002, was well attended with more than 100 attendees from a large number of countries, including USA and Japan ( Fig.1).

Fig.1. More than 100 delegates attended the 2 ^nd EuroStir ^® Workshop at TWI
© 2003, TWI Ltd

In the foyer an exhibition was held, promoting the services and products provided by the Collaborators of the EuroStir ^® project ( Fig.2-5). Especially for delegates from small and medium sized companies, there was an opportunity to attend EuroStir ^® Clinics to discuss welding related applications on a one-to-one basis with the experts.

Fig.2. TWI's exhibition stand at the 2 ^nd EuroStir ^® Workshop at TWI
© 2003, TWI Ltd

The programme of the 2 ^nd EuroStir ^® Workshop was as follows:

Welcome and Introduction to the EuroStir ^® Project

Dr Torben Lorentzen (Managing Director, DanStir).

Technical Benefits of FSW

David Nicholas (Business/Technology Development Manager, Friction & Forge Processes, TWI).

Fig.3. TWI's small CNC controlled demonstration machine was shown in the EuroStir ^® exhibition in the Foyer of TWI's Conference Center
© 2003, Olecon Oy

Exhibition stand of Seco Aluminium, a UK company specialising in aluminium extrusions

Fig.4. 'Aluminium for future generations' was the theme of the exhibition stand of Seco Aluminium, a UK company specialising in aluminium extrusions ^[1]
© 2003, TWI Ltd

Fig.5. Five papers on FSW developments and applications were presented by the EuroStir ^® Collaborators
© 2003, TWI Ltd

Current and Potential Friction Stir Welding Applications

Stephan Kallee, (Collaborative Project Manager, Friction & Forge Welding Processes, TWI).

Robotic Friction Stir Welding: Technology and Applications

Dr Jorge dos Santos (Group Manager, Institute for Materials Research Joining Technology, GKSS).

Jobbing Shop Activities

Dr Torben Lorentzen (Managing Director, DanStir).

FSW for Profitability

Johnny Sundin (Design Manager, Engineering Division, ESAB Welding Equipment AB ^[2] , Fig.6).

ESAB demonstrated the low level of distortion that can be achieved by using their CNC controlled SuperStir machines

Fig.6. ESAB demonstrated the low level of distortion that can be achieved by using their CNC controlled SuperStir ^TM machines
© 2003, TWI Ltd

In the afternoon live demonstrations of friction stir welding and other joining technologies were given ( Fig.7).

Fig.7. TWI's large gantry-type laboratory FSW machine was demonstrated at up to 6m/min welding speed
© 2003, TWI Ltd

Demo 1 - FSW of Copper

Machine: ESAB SuperStir ^TM, FW28, high-force head.
Material: HDHC (high-density, high-conductivity) Copper, 8mm thick ( Fig.8-10).
Geometry of joint: Butt joint, 400mm long.
FSW Tool: 2° tilt, concave shoulder, round pin with two flats.
Pilot hole: dia 9mm.
Traverse speed: 150mm/min (60mm/min for first 40mm).
Control of tool heel plunge depth: Position control.
Clamping: Side clamped and roller, existing jig.

A hydraulically actuated roller was used to press the copper sheets firmly onto the backing bar of the FSW machine operated in 'position control' mode

Fig.8. A hydraulically actuated roller was used to press the copper sheets firmly onto the backing bar of the FSW machine operated in 'position control' mode
© 2003, TWI Ltd

Fig.9. FSW of copper will change the assembly methods in the electrical and power generation industry, e.g. when producing coils for electrical motors or buss bars
© 2003, TWI Ltd

Demo 2 - High-speed FSW of Thin Aluminium Sheets

Machine: ESAB SuperStir ^TM FW28, low-force head.
Material: Aluminium alloy 6023-T4, 1.2mm thick ( Fig.11).
Geometry of joint: Butt Joint - 2m long.
FSW Tool: EuroStir ^® 1.2mm MX Triflute ^TM tool, developed in TWI's Core Research Programme.
Pilot hole: No.
Traverse speed: 6000mm/min.
Control of tool heel plunge depth: Position control, using roller.
Clamping: Vacuum clamped.

Demonstration of a 1.2mm thick aluminium panel at 6m/min welding speed

Fig.11. A 1.2mm thick aluminium panel was welded during the EuroStir ^® demonstrations at 6m/min welding speed
© 2003, Olecon Oy

Demo 3 - Modular FSW Machine

Machine: Modular ESAB LEGIO ^TM SuperStir ^TM.
Operators: Peter Söderberg et al (ESAB, Fig.12-14).
Material: 6000 series aluminium alloy, 6mm thick.
Geometry of joint: Butt joint.
FSW Tool: Proprietary.
Pilot hole: No.
Traverse speed: 2000mm/min.
Control of tool heel plunge depth: Position control.

ESAB demonstrated a modular LEGIO machine in TWI's new Engineering Hall

The ESAB LEGIO machines can be purchased in a package including an FSW licence

The modular design of the ESAB LEGIO machines can be adapted for a wide variety of workpieces

Fig.14. The modular design of the ESAB LEGIO ^TM machines can be adapted for a wide variety of workpieces
© 2003, TWI Ltd

During the tour there was also the opportunity to visit TWI's HVOF thermal spraying (high velocity oxy fuel) and adhesive bonding laboratories.

References

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Second EuroStir ^® Workshop at TWI: 'Friction Stir Welding - an intensive interactive day on the technical and economic benefits' (6 Nov 2002)

Fig.1. More than 100 delegates attended the 2 ^nd EuroStir ^® Workshop at TWI
© 2003, TWI Ltd

Fig.2. TWI's exhibition stand at the 2 ^nd EuroStir ^® Workshop at TWI
© 2003, TWI Ltd

Welcome and Introduction to the EuroStir ^® Project

Technical Benefits of FSW

Fig.3. TWI's small CNC controlled demonstration machine was shown in the EuroStir ^® exhibition in the Foyer of TWI's Conference Center
© 2003, Olecon Oy

Fig.4. 'Aluminium for future generations' was the theme of the exhibition stand of Seco Aluminium, a UK company specialising in aluminium extrusions ^[1]
© 2003, TWI Ltd

Fig.5. Five papers on FSW developments and applications were presented by the EuroStir ^® Collaborators
© 2003, TWI Ltd

Current and Potential Friction Stir Welding Applications

Robotic Friction Stir Welding: Technology and Applications

Jobbing Shop Activities

FSW for Profitability

Fig.6. ESAB demonstrated the low level of distortion that can be achieved by using their CNC controlled SuperStir ^TM machines
© 2003, TWI Ltd

Fig.7. TWI's large gantry-type laboratory FSW machine was demonstrated at up to 6m/min welding speed
© 2003, TWI Ltd

Fig.8. A hydraulically actuated roller was used to press the copper sheets firmly onto the backing bar of the FSW machine operated in 'position control' mode
© 2003, TWI Ltd

Fig.9. FSW of copper will change the assembly methods in the electrical and power generation industry, e.g. when producing coils for electrical motors or buss bars
© 2003, TWI Ltd

Fig.10. Triton Tooling machined the MX Triflute ^TM tools for welding copper ^[3]
© 2003, TWI Ltd

Fig.11. A 1.2mm thick aluminium panel was welded during the EuroStir ^® demonstrations at 6m/min welding speed
© 2003, Olecon Oy

Fig.12. ESAB demonstrated a modular LEGIO ^TM machine in TWI's new Engineering Hall
© 2003, TWI Ltd

Fig.13. The ESAB LEGIO ^TM machines can be purchased in a package including an FSW licence
© 2003, TWI Ltd

Fig.14. The modular design of the ESAB LEGIO ^TM machines can be adapted for a wide variety of workpieces
© 2003, TWI Ltd

References

Second EuroStir ® Workshop at TWI: 'Friction Stir Welding - an intensive interactive day on the technical and economic benefits' (6 Nov 2002)

Fig.1. More than 100 delegates attended the 2 nd EuroStir ® Workshop at TWI © 2003, TWI Ltd

Fig.2. TWI's exhibition stand at the 2 nd EuroStir ® Workshop at TWI © 2003, TWI Ltd

Welcome and Introduction to the EuroStir ® Project

Technical Benefits of FSW

Fig.3. TWI's small CNC controlled demonstration machine was shown in the EuroStir ® exhibition in the Foyer of TWI's Conference Center © 2003, Olecon Oy

Fig.4. 'Aluminium for future generations' was the theme of the exhibition stand of Seco Aluminium, a UK company specialising in aluminium extrusions [1] © 2003, TWI Ltd

Fig.5. Five papers on FSW developments and applications were presented by the EuroStir ® Collaborators © 2003, TWI Ltd

Current and Potential Friction Stir Welding Applications

Robotic Friction Stir Welding: Technology and Applications

Jobbing Shop Activities

FSW for Profitability

Fig.6. ESAB demonstrated the low level of distortion that can be achieved by using their CNC controlled SuperStir TM machines © 2003, TWI Ltd

Fig.7. TWI's large gantry-type laboratory FSW machine was demonstrated at up to 6m/min welding speed © 2003, TWI Ltd

Fig.8. A hydraulically actuated roller was used to press the copper sheets firmly onto the backing bar of the FSW machine operated in 'position control' mode © 2003, TWI Ltd

Fig.9. FSW of copper will change the assembly methods in the electrical and power generation industry, e.g. when producing coils for electrical motors or buss bars © 2003, TWI Ltd

Fig.10. Triton Tooling machined the MX Triflute TM tools for welding copper [3] © 2003, TWI Ltd

Fig.11. A 1.2mm thick aluminium panel was welded during the EuroStir ® demonstrations at 6m/min welding speed © 2003, Olecon Oy

Fig.12. ESAB demonstrated a modular LEGIO TM machine in TWI's new Engineering Hall © 2003, TWI Ltd

Fig.13. The ESAB LEGIO TM machines can be purchased in a package including an FSW licence © 2003, TWI Ltd

Fig.14. The modular design of the ESAB LEGIO TM machines can be adapted for a wide variety of workpieces © 2003, TWI Ltd

References

Second EuroStir ^® Workshop at TWI: 'Friction Stir Welding - an intensive interactive day on the technical and economic benefits' (6 Nov 2002)

Fig.1. More than 100 delegates attended the 2 ^nd EuroStir ^® Workshop at TWI
© 2003, TWI Ltd

Fig.2. TWI's exhibition stand at the 2 ^nd EuroStir ^® Workshop at TWI
© 2003, TWI Ltd

Welcome and Introduction to the EuroStir ^® Project

Fig.3. TWI's small CNC controlled demonstration machine was shown in the EuroStir ^® exhibition in the Foyer of TWI's Conference Center
© 2003, Olecon Oy

Fig.4. 'Aluminium for future generations' was the theme of the exhibition stand of Seco Aluminium, a UK company specialising in aluminium extrusions ^[1]
© 2003, TWI Ltd

Fig.5. Five papers on FSW developments and applications were presented by the EuroStir ^® Collaborators
© 2003, TWI Ltd

Fig.6. ESAB demonstrated the low level of distortion that can be achieved by using their CNC controlled SuperStir ^TM machines
© 2003, TWI Ltd

Fig.7. TWI's large gantry-type laboratory FSW machine was demonstrated at up to 6m/min welding speed
© 2003, TWI Ltd

Fig.8. A hydraulically actuated roller was used to press the copper sheets firmly onto the backing bar of the FSW machine operated in 'position control' mode
© 2003, TWI Ltd

Fig.9. FSW of copper will change the assembly methods in the electrical and power generation industry, e.g. when producing coils for electrical motors or buss bars
© 2003, TWI Ltd

Fig.10. Triton Tooling machined the MX Triflute ^TM tools for welding copper ^[3]
© 2003, TWI Ltd

Fig.11. A 1.2mm thick aluminium panel was welded during the EuroStir ^® demonstrations at 6m/min welding speed
© 2003, Olecon Oy

Fig.12. ESAB demonstrated a modular LEGIO ^TM machine in TWI's new Engineering Hall
© 2003, TWI Ltd

Fig.13. The ESAB LEGIO ^TM machines can be purchased in a package including an FSW licence
© 2003, TWI Ltd

Fig.14. The modular design of the ESAB LEGIO ^TM machines can be adapted for a wide variety of workpieces
© 2003, TWI Ltd