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TWI Core Research Programme - the results

TWI Bulletin, January - February 1996

 

Graham Wylde
Graham Wylde

Graham Wylde joined TWI in 1975 to carry out research and development programmes on fatigue design of welded structures. He is now Product Manager - Information and Core Services at TWI, and Head - Industrial Member Services Department.

One of the most important features that sets TWI apart from many other Research and Consultancy organisations is its Core Research Programme (CRP). This programme is funded from the annual technology access fees paid by TWI's Industrial Members. As Graham Wylde explains, the programme runs on a three year cycle, the present series of projects started at the beginning of 1995.




The current programme has some 56 projects covering all aspects of joining and related technologies. These projects are listed in the Table . It is important that Industrial Members appreciate how they can access results of the CRP, both in the form of the final reporting and also during the work. The CRP is a confidential programme, with the results issued exclusively to Industrial Members for a period before publication in open literature. This period is set by The Research Board which comprises representatives from the membership. This gives Industrial Members priority access to the findings, and with this, the opportunity to assess how the information can be used within their organisation before the results become openly available.

Fig. 1: Fatigue testing of a girth weld
Fig. 1: Fatigue testing of a girth weld

Throughout its history the programme has led to a number of major developments and advances in materials joining technology. Industrial Members should take some pride in their contribution to this programme. Each year the top achievements are listed in TWI's Annual Review which in recent years has been incorporated in the Annual Report.

Fig. 2: Sampling of welding gases
Fig. 2: Sampling of welding gases

In terms of the findings of the programme, these are made available to Industrial Members in a number of ways:

Members Reports

At the end of each programme, or at suitable progress points, detailed reports of the work and the results are issued in the form of Member Reports. These reports are generally of a detailed nature and they are distributed in two ways of the Member's choice:

  • They can automatically receive all reports as they are issued (on average 2-3 each month).
  • They can request those reports which they feel will be of particular interest, or relevance to their business.

It is suggested that larger companies who have a library or other central source of reference material may wish to request a complete set of reports for this location, with other staff requesting copies of reports relevant to their specific interests.

Fig. 3: Wire bonding (ball bonding)
Fig. 3: Wire bonding (ball bonding)
Fig. 4: Inspection of microelectronic assembly
Fig. 4: Inspection of microelectronic assembly
Fig. 5: Laser cutting thick sheet
Fig. 5: Laser cutting thick sheet

Bulletin

TWI's Bulletin contains shorter articles from the CRP programmes. These may be taken from projects which The Research Board felt could be better disseminated in the form of a Bulletin article than as a full report, or they may form one part of work also covered more fully as an entire Member Report.

Technology Briefings

Technology Briefings were introduced in 1993 as a direct result of comments received from some Industrial Members who felt the need for an alternative reporting format - one that would provide a brief summary, ie the main technical achievements and benefits of the work, in addition to the full results in the Member Reports. These have proved very popular with Members.

In 1996, TWI changed the way that these reports were distributed to Members; Technology Briefings are incorporated into the Bulletin. This should have the main benefit that they can be readily filed and kept for easy access. The very brief summaries of the more detailed Member Reports that were previously included in the Bulletin (as New Reports) have been discontinued. Industrial Members who wish to obtain the full report should use the accompanying form, or a photocopy, as in the past.

It is hoped that Members will find this method of distribution an improvement over the previous system. The Technology Briefings will continue to be numbered in sequence with the full Member Reports. Thus the first of the new style will be: 539/1996.

Fig. 6: Friction stir welding of aluminium alloy
Fig. 6: Friction stir welding of aluminium alloy

Discussions

In addition to the formal reporting lines for the CRP projects it is most important that Industrial Members take the opportunity to discuss progress of ongoing programmes with staff at TWI. This form of interaction is positively encouraged and will have benefits for both parties.

For the Members it provides a means of keeping up to date with new developments which may have a significant impact on their business well before the results are published. It also provides a valuable opportunity to contribute ideas to the programme and to ensure that the work meets the requirements of industry. On occasions it may also be possible to contribute materials, consumables or equipment for inclusion in the programme.

For the TWI staff member it provides that essential link with those in industry who are likely to find most use for the results. This ensures that the work is allied closely to the needs of industry and provides vital verification that the work is likely to be of value to Members.

Next time you visit Abington please take the opportunity to identify which of the current programmes are of most relevance to your business and also to discuss the work with the project leader.

Table: TWI Core Research Programme 1995-97

Project title Project leader
Reliability/probabilistic approach to flaw assessment (9401-1) H G Pisarski
Fracture predictions using the 'Local Approach' (9401-2) C S Wiesner
The effect of weld metal mismatch and residual stresses on integrity assessment
calculations (9401-3)
S D Smith
Fracture mechanics testing (9401-4) I Hadley
Flaw characterisation using non-destructive methods (9401-5) A M Lank
Mathematical modelling of NDT inspection methods for surface engineering processes (9401-6) G Georgiou
Real time assessment of corrosion damage (9402-1) A T Smith
Rationalisation of PWHT(9402-2) R H Leggatt
Fatigue performance demonstration research need (9402-3) P J Tubby
Creep performance of welded plant (9402-4) R Phaal
Performance and reliability of ultrasonic inspection techniques (9402-5) B Kenzie
Relevance of proof testing to the performance of engineering structures (9402-6) K Bell
NDT of environmentally assisted cracking (9402-7) A B Day
Inspection strategies (9402-8) C I K Sinclair
Weld metal development for modified 9%Cr1%Mo (grade 91) steels (9403-1) A M Barnes
Control of fabrication hydrogen cracking in steels of 350-550 N/mm 2 yield strength (9403-2) A J Kinsey
Solidification cracking in steel laser welds (9403-3) G Reed
Development of tough microstructures in low oxygen weld metals (9403-4) M T Harvey
Welding new stainless steels for optimum corrosion resistance (9403-5) P Woollin
Effect of intermetallic precipitates on the fracture toughness of duplex stainless steel weldments (9403-6) R N Gunn
Weldability of new titanium alloys by conventional and high productivity processes (9404-1) M F Gittos
Environmental hydrogen cracking behaviour or welded ferritic steels (9404-3) D Buxton
Evaluation of sampling protocol defined by European standard ENXXXX Health and Safety in
Welding and allied processes - sampling of airborne particles & gases in the operator'sbreathing zone (9404-4)
G J Carter
Novel glass-ceramic techniques for bonding ceramics to metals (9405-1) W B Hanson
Improved high-temperature brazed ceramic to metal joints (9405-2) W B Hanson
Joining of intermetallic alloys (9405-3) P L Threadgill
Intermetallic and ceramic coatings for high temperature corrosion resistance (9405-4) A J Sturgeon
Improved hardfacing consumables for plasma and HVOF spraying (9405-5) F J Blunt
Hard protective coatings for soft substrates (9405-6) A Taylor
Structural integrity of plastics welds (9406-1) M Troughton
Performance predictions for adhesively bonded joints under fatigue loading (9406-2) M Tavakoli
Performance of conductive adhesives in flip chip and ball grid array interconnection (9406-3) P M Bartholomew
Increasing wire bonding yields (9406-4) C J Foster
The formation of ultrasonic welds at the molecular level (9406-5) R J Wise
Sealing of plastics films and fabrics (9406-6) R Hardy
Cost effective micromachining/deposition techniques (9406-7) C J Foster
Surface active fluxes (9407-1) D S Howse
Microwaves for material processing (9407-2) W Lucas
Laser welding of complex geometries (9407-3) I A Jones
Process development using new high power laser sources (9407-4) I A Jones
Improved monitoring and control of laser and arc processes (9407-5) G Wlodarczyk
Hybrid joining techniques (9407-6) S A Westgate
Manufacturing process control for robotic resistance welding applications (9407-7) H J Powell
Portable robot - advanced applications (9408-1) K Wiemer
Predicting and reducing distortion due to welding (9408-2) P C J Anderson
Enhanced cutting processes (9408-3) D S Howse
Repair welding of medium carbon engineering steels without post-weld heat treatment (9408-4) W Lucas
Knowledge based software (9408-5) A D Brightmore
Software with advanced user interfaces (9408-6) M A Bourton
High intensity beams for material processing at low and medium power levels (9409-1) C N Ribton
Enhanced penetration with non-vacuum electron beams for welding and cutting (9409-2) A Sanderson
Electron beam texturing for dissimilar material joining (9409-3) B G I Dance
Friction stir welding of metals (9409-4) C J Dawes
Friction hydro pillar processing (FHPP) (9409-5) R E Andrews
Emerging friction based processes (9409-6) W M Thomas

For further details contact the relevant Project Leader at TWI, Abington, Cambridge CB1 6AL.
Tel: +44 (0)1223 899000 or Fax: 01223 892588