ALLUMINIO ALLUMINIO E E LEGHE LEGHE

The joining of aluminium extrusions

R. E. Dolby, K. I. Johnson, W. M. Thomas

saldatura mediante FSW di particular emphasis on aluminium extruded and rolled products. pe44i estrusi e a se4ione cava The tool employed during FSW is critical in determining weld uality and reliability, particularly the a) supporto a mandrino probe. !robe types developed to"date are described, together with their main areas ofripiegabile application. #ecent b) supporto a form rotelle and developments in probes for butt"welding include the Whorl T$ and $%"Triflute T$ and the c) supporto a camera T$ and advantages of these are presented. &ap welding by FSW is more difficult than butt. Flared"Triflute d5aria3incudine idraulico the '"S(ewT$ tools are currently under development for lap welding and show great promise in overcoming these difficulties. Parole chiave aluminum! "el#ing

The basic principle of Friction Stir welding (FSW) is described and recent applications Fig 0 Supporti per la reviewed, with

Fig 0 1xtrusion 2 hollow section supports for FSW a) collapsible mandrel support b) roller support c) hydraulic bladder3anvil support

INT$O%U&TION It has long been recognised that frictional heating can be used to join, process and treat materials. Friction stir welding (FSW) is a process for joining workpieces in the solidphase, using an intermediate non-consumable tool made of material that is harder than the workpiece material being welded (see fig ). FSW is a continuous hot shear process in!ented and patented b" #WI in $$ . It in!ol!es slowl" plunging a portion of a speciall" shaped rotating tool between, and then along, the abutting faces of the joint. #he marked difference between the ele!ated temperature properties of the tool and the workpiece, along with a suitable c"clic mo!ement between the tool and the workpiece, generates sufficient frictional heat to cause plasticised (third-bod") conditions in the workpiece material. #he contacting surface of the shoulder of the tool and the length of the probe below the shoulder essentiall" allow the probe to maintain penetration to the re%uired through-thickness depth. Initiall" FSW was confined to relati!el" soft workpiece materials such as aluminium, lead, &inc and magnesium. 'owe!er, the weldabilit" of copper, steel and titanium allo"s has also been demonstrated ( -(). #he welding of such harder workpiece materials has been possible b" maintaining a suitable differential between the ele!ated temperature properties of the tool and of the workpiece materials. )lthough incipient melting during welding has been reported for some materials, FSW can be regarded as a solid state, autogenous ke"hole joining techni%ue. #he weld metal is thus free from defects t"picall" found when fusion welding, eg porosit". Furthermore, and unlike fusion welding, no consumable filler material or profiled edge preparation is normall" necessar". FSW is now a practical techni%ue for welding aluminium rolled and e*truded products, ranging in thickness from 1.( to ,( mm, and In!ariabl" manufacturers is used in commercial aim to fabricate production their products worldwide. as fast #he as possible. present paper Increasing describes the welding the current speed state or,of for application certain appliof the process, cations, the usetogether of purpose with designed future possible multi-headed applications. frictionIt stir also co!ers welding machines, recent de!elopments can increase producti!it" in tool design and asprofitabilit". this is the ke" to the Figure 9 illustrates successful a design application concept of the forprocess. an opposed rotation multi-head friction stir welding machine. Such opposed tool rotation balances side force as"mmetr" and enables a reduction in the clamping force needed to hold the plates together.
$* E* %ol+,! -* I* .ohnson! )* M* Thomas TW+ &td, ,t 'bington, -ambridge, ./ 4aper presented at the/ )luminium #wo #housand, (th World 5ongress, 6ome .-77 8arch 7119

Fig 6 $ulti"head friction stir welding Fig ) *asic principle of the FSW process Fig 6 Saldatura FSW a testa Fig ) !rincipio di base del processo multipla FSW

APPLI&ATION' O( (') )lthough FSW was onl" in!ented "ears ago, its current industrial application is substantial, but to-date is mostl" confined to the butt welding of aluminium rolled and e*truded products. )pplications ha!e been recentl" re!iewed (+, , - .) and include welding of the following aluminium components/ 0 e*truded panels for fishing boat free&ing e%uipment(.) 0 e*truded high speed ferr" panels(.) 0 e*truded floor and bod" panel for rail rolling stock(.) 0 rolled trol of asheet number fuel of tanks parameters. for aerospace ) ke" applications(,) factor in ensuring weld %ualit" is thefor use of an appropriate tool. 0 wrought wheels automoti!e applications(+) 0 e*truded2wrought #he importance of the automoti!e tool is illustrated suspension in the arms(+) following recent e*ample in!ol!ing the lap welding of +mm (1.9-1 con3ther applications which are acti!el" being de!eloped for production dition aluminium include/ allo" wrought sheet. In preliminar" trials a con!entional c"lindrical pin panels(.,+) probe tool was used 0 tailor welded blanks forthreaded automoti!e 0 wrought which ga!e components a good as-welded for aerospace appearance. rocket 'owe!er, frames(,) bend testing showed the weld to be for weak due to e*cessi!e thin0 wrought airframe structures ci!il aircraft(,) Withof ning regard the top to more sheet long-term and thickening applications, of the bottom in!estigations sheet caused b" aare pressure differential during Fig :. of at #WI continuing to e*plore andwelding, de!elop see a number techni%ues #he failure for followed welding the e*trusions original interfacial and hollow surface sections. o*ide la"ers which, in (1.9-1 condition material, are known to be FSW of certain thin walled hollow sections re%uires internal mandrel support, particularl" tenacious. e.g. a mo!ing an!il or a h"draulicall" ac#he abo!e problems were caused because, tuated or scissor action support, see Fig 7a,although b - c. the tool la metallurgia italiana

(') TOOL'

)lthough FSW consistentl" gi!es high %ualit" welds this can onl" be achie!ed b" proper use of the process and con-

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#his e*ample abo!e illustrates that good welding can onl" be achie!ed b" the use of a tool appropriate to the application and a number of tools ha!e been de!eloped at #WI o!er the last "ears to accommodate a number of materials, component thicknesses and joint t"pes, as shown in Fig (. Tools (or /utt )el#ing #he con!entional c"lindrical threaded pin probe is ade%uate for butt welding aluminium of thickness up to ; 7mm. When welding thicker plate the Whorl # 8 and 8<-#riflute # 8 should be used. )s Fig ( indicates these are capable of welding up to (1mm and +1mm thicknesses respecti!el". #"pical forms of these tools are shown in Figs + and ,. #hese tools ha!e an additional benefit in that the" are capable of welding speed =*7 that achie!able with the con!entional probe. >oth t"pes of probe ha!e flat or re-entrant features or, in the case of certain Whorl # 8 probes, an o!al cross-section, which reduce the probe !olume and achie!e a suitable swept !olume to static !olume ratio. #he greater the swept to static !olume ratio, the greater the path for material flow and the more efficient is the probe. In addition, these re-entrant features, especiall" the helical coarse ridges around the lands, help break up and disperse the surface o*ides within the joint region. Tools (or La0 )el#ing ?ap welding b" FSW is more difficult than butt welding as/ 0 wider welds are necessar" to transmit the load properl" in the manufactured structure

Fig 7 8and bend tested lapweld in 9mm thic(, :;<6"; condition sheet made at a welding speed of 0mm=sec ()0;mm=min). Severe plate thinning on the retreating side of the top plate (see Fig )) is evident Fig 7 Saldatura a sovrapposi4ione curvata a mano in una lamiera in lega :;<6"; dello spessore di 9mm a una velocit> di saldatura di 0mm=sec ()0;mm=min). 15 evidente un severo assottigliamento sul lato retratto della lamiera superiore (Fig ))

emplo"ed ga!e satisfactor" welds when butt welding plate components, its use when lap welding was inappropriate. ?ap welding re%uires a modified tool to ensure full disruption of the interfacial o*ide la"ers and a wider weld than is re%uired when butt welding.
Fig : !robe types developed at TW+ for various material thic(nesses and ?oint types Fig : Tipi di sonde sviluppate alla TW+ per diversi spessori di materiali e tipi di saldatura

Fig 9 *asic variants for the WhorlT$ type probes Fig 9 varianti di base delle sonde WhorlT $

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Fig @ Flare"TrifluteT $ tool with lap welding whis( profile positioned across the weld interface Fig @ 'ttre44atura Flare"Triflute T$ con profilo per la saldatura di pe44i sovrapposti posi4ionato atraverso l5interfaccia di saldatura

Fig A Typical $%"TrifluteT $ probe Fig A Tipica sonda $%"Triflute T $ Fig < -omparative stress flow lines (a) Barrow weld width " high stress concentration (b) Wide weld width " low stress concentration Fig < &inee comparative del flusso di tensioni (a) larghe44a di una saldatura stretta C alta concentra4ione di tensione (b) larghe44a di una saldatura larga" bassa concentra4ione di tensione

abc

Fig ); !rototype '"S(ewT$ !robe a) Side view b) Front view, showing probe profile c) Swept region encompassed by s(ew action during welding Fig ); Sonda prototipo '"S(ewT$ a) vista laterale b) vista frontale che mostra il profilo della sonda c) #egione circondata dall5a4ione obli ua durante la saldatura

0 the form of the notch, particularl" at the tip at the edge of the weld, must be modified to ensure ma*imum strength (particularl" fatigue strength) of the manufactured structure 0 the o*ide disruption at the sheet interface is more difficult because of the orientation of the joint interface and the FSW tool With regard to the width of the weld, Fig . illustrates that stress is concentrated more se!erel" at the notch tips of unbonded regions when the weld width is reduced. #his assumes that the morpholog" of the tip region in both the narrow

and wide welds is similar. #he detailed morpholog" of the notch tip either side of the weld is critical to joint mechanical performance. Special tools are under de!elopment to minimise the e*tent of the tip area and control its orientation with respect to the sheet interface, specificall" the Flared-#riflute # 8 and )-Skew #8 , see Fig (. #he forms of these tools are shown in Figs $ and 1. ) lap joint made with a Flared-#riflute # 8 probe is shown in Fig (a). In this e*ample the width of the weld region is $1@ of the plate thickness and little upper plate thinning is apparent. (#he corresponding figure achie!ed when using a con!entional threaded pin probe is 1@). #he notch tip at the edge of the weld achie!ed using this tool is shown in Figs (b) and (c). It should be noted that the tip at the retreating side (Fig (b)) does not lie in a direction perpendicular to the sheet interface as it does when a weld made with a con!entional pin probe is emplo"ed. #he tip at the ad!ancing side (Fig (c)), howe!er, turns in a direction perpendicular to the sheet interface, but this is much less pronounced than obtained when a con!entional pin is used. 8ore promising results ha!e also been achie!ed with the )Skew# 8 tool. Fig 7 shows a weld made at the same conditions as Fig , but using this tool. Figs 7 (b) and (c) show a much impro!ed alignment of the edge notch, e!en on the ad!ancing side. >end testing of the abo!e welds further showed that the o*ide disruption at the sheet interface was significantl" greater than achie!ed with the con!entional pin probe. #he latter

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Fig.)) &apweld made using a Flared"TrifluteD probe in 9mm thic( :;<6"; condition aluminium alloy, at a welding speed of 7mm3sec (07;mm3min) a) $acrosection b) Eetail of notch at the retreating side c) Eetail of notch at the advancing side Fig.)) Saldatura di pe44i sovrapposti ottenuta con sonda Flared" TrifluteD in una lega di alluminio :;<6"; dello spessore di 9mm, con velocit> di saldatura di 7mm3sec (07;mm3min) a) $acrose4ione b) Eettaglio di un intaglio nel lato retratto c) Eettaglio di un intaglio nel lato avan4ato

Fig. )0 &apweld made using a '"S(ewT$ probe in 9mm thic( :;<6"; condition aluminium alloy at a welding speed of 7mm3sec (07;mm3min) a) $acrosection b) Eetail of notch at the retreating side c) Eetail of notch at the advancing side Fig. )0 Saldatura di pe44i sovrapposti ottenuta con sonda '" S(ewT$ in una lega di alluminio :;<6"; dello spessore di 9mm, con velocit> di saldatura di 7mm3sec (07;mm3min) a) $acrose4ione b) Eettaglio di un intaglio nel lato retratto c) Eettaglio di un intaglio nel lato avan4ato

showed failure earl" in the bend test t"picall" as shown in Fig :, whilst the former ga!e welds which were capable of =$1A bend without failure. 4romising results are being

achie!ed in fatigue tests on o!erlap welds made with the two tool t"pes. #esting is currentl" in progress, together with tool de!elopment. la metallurgia italiana

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'UMMA$1 AN% &ON&LU'ION #his paper describes current applications of FSW on wrought and e*truded aluminium products and patented techni%ues for use on hollow e*trusions. 6ecent de!elopments in FSW butt and lap-welding of such materials are also outlined - particularl" a Flared-#rifluteK probe and an )SkewK probe. >oth gi!e lap welds of $1@ of the plate thickness, an impro!ement in weld integrit", a reduction in upper plate thinning and an increased welding speed o!er current practice. )lthough significant impro!ements ha!e been achie!ed, additional tool de!elopment work is underwa" to further minimise the occurrence and se!erit" of defects associated with FSW lap welds. A&-NO)LE%GEMENT' #he authors wish to thank H L Staines, I 8 Eorris, J H Eicholas, 4 ? #hreadgill, I F Smith, J 6 Watts, ) ?eonard, ) Huncan and 4 J!ans. $E(E$EN&E' ) >oon #, #homas W.8 and #emple-Smith 4/ Friction welding apparatus and method 4atent Eo. NS +,97(,7,9 > (priorit" date Hecember +, $$+) 7) )ndersson 5 L, )ndrews 6 J, Hance > L I, 6ussell 8 F 3lden J F, - Sanderson 6 8, M) comparison of copper canister fabrication b" the electron beam and friction stir processesC. Swedish Euclear Fuel and Waste 8anagement 5o (SG>) and #WI. st FSW S"mposium, :- + Fune $$$, #housand 3aks, 5alifornia, NS). 9) 5olligan G F, Fisher F F, Lo!er J F, - 4ickens F 6, IFriction stir welding in the ad!anced amphibious assault !ehicleI, )d!anced 8aterials and 4rocesses, September 7117. :) 8ishra 6 S, 8ahone" 8 W, 8cFadden S <, 8ara E ) and 8ukherjee ) G/ M'igh strain rate superplasticit" in friction stir welding processed ,1,( )l allo"C. Scripta 8aterialia, :7 (7111), pp. +9- +., 3ctober $$$. () Hawes 5 F/ MFaster and faster B welding speed increases

with tool de!elopment B one of a series of stepsC. >ulletin Dol. : Eo. :, Ful"2)ugust 7111, pp.( -((. +) Gallee S W, Eicholas H. IFriction and forge welding processes for the automoti!e industr"I. International >od" Jngineering 5onference, Hetroit, 7.-91 September $$$, $$-I>J55- 9. ,) Gallee S W, Eicholas J H, #homas W8. IIndustrialisation of Friction stir welding for aerospace structuresI. Structures and #echnologies - 5hallenges for Future ?aunchers #hird Juropean 5onference, - : Hecember 711 , Strasbourg, France. .) Ha!enport F, Gallee S W - W"lde F L. IJurope follows Fapan into friction stir weldingI. 6ailwa" La&ette, Eo!ember 711 . $) Jricsson 8, IFatigue strength of friction stir welded joints in aluminiumI, ?icentiate thesis, Hepartment of 8aterials Science - Jngineering, 6o"al Institute of #echnolog" (G#') S- 11:: Stockholm, Sweden, 8a" 7117. 1) >rooker 8 F, !an Heudekom ) F 8, Gallee S W, Sketchle" 4 H/ M)ppl"ing Friction Stir Welding to the )raine ( 8ain 8otor #hrust FrameC. Fokker 4aper, Juropean 5onference on Spacecraft Structures, 8aterials and 8echanical #esting, 7$ Eo! B Hec 7111, Jstec, Eoordwijk, #he Eetherlands. ) 5eder%uist ? and 6e"nolds ).4/ Factors affecting the properties of friction stir welded aluminium lap joints Welding research supplement, (Hecember 711 ), pp 7. -7.,. 7) 5hristner >, IHe!elopment and testing of friction stir welding (FSW) as a joining method for primar" aircraft structureI, I5)S 5ongress 7117. 9) 8atsumoto G - Sasabe S/ M?ap Foints of )luminium )llo"s b" Friction Stir WeldingC. 4roc. 9rd International Friction Stir Welding S"mposium, Gobe, Fapan, 7,7. Sept, 711 . :) Smith 5 >, 5rusan W, 'ootman F 6, 'inrichs F F, 'eideman 6 F, Eoruk F S. IFriction stir welding in the automoti!e industr"I. #ower )utomoti!e - #echnolog" )pplication, 9(99 E 7,th St, 8ilwaukee WI, (97 +. () #homas W 8, >raithwaite ) > 8, - Fohn 6/ MSkewStirK technolog"C 4roc. 9rd International Friction Stir Welding S"mposium, Gobe, Fapan, 7,-7. Sept, 711

A/'T$ A&T

'AL%ATU$A %I E'T$U'IONI %I ALLUMINIO

KEYWORDS: alluminio e leghe, sal atura

Bella memoria si descrive principio di base della tecnica di saldatura denominata Friction Stir welding (FSW) e si offre una panoramica delle recenti applica4ioni, con particolare rilievo sui prodotti di alluminio estrusi e laminati. &Iattre4" 4atura impiegata per il FSW, e in particolare la sonda, G de"

terminante per la ualit> e affidabilit> della saldatura. Fen" gono descritti i tipi di sonda attualmetne disponibili e i loro campi di applica4ione principali. ,li sviluppi recenti delle sonde per saldatura includono WhorlT$ e $%"TrifluteT$ e vengono presentati la loro forma ed i loro vantaggi. &a sal" datura mediante FSW di parti sovrapposte G piH difficile della saldatura di estremit>. 'ttualmente sono in via di svi" luppo le promettenti apparecchiature Flared"TrifluteT$ e '"S(ewT$ per la saldatura di parti sovrapposte che per" metteranno di superare ueste difficolt>.

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