Linear Friction Welding Technology Update -...
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Copyright © TWI Ltd 2015
Bertrand FlipoFriction and Forge Processes
Linear Friction WeldingTechnology Update
Copyright © TWI Ltd 2015
Automated, repeatable, fast, dependable weldsNear-net-shape additive manufacturing of forged parts
Enables advanced structures through material tailoringOpens to new design freedoms, and reduces part count
Helps to control material input and product time-to-market
Linear Friction Welding: bottom line
Copyright © TWI Ltd 2015
TWI Non–governmental Not for profit distributing Independent Impartial
TWI’s mission:To be the best at what we do** To deliver world class services in joining materials, engineering and allied technologies to meet the needs of a global membership and its associated community
Dedicated to Materials Joining Over $100m R&D per year Over 850 staff in 4 UK centres Over 700 Industrial Members 60 years track record
World Centre for Materials Joining
Copyright © TWI Ltd 2015
Based in Cambridge
16 Engineers and Technicians
53 years of R&D in Friction Processes One of the first in Friction Welding Pioneered Linear Friction Welding Invented Friction Stir Welding
TWI - Friction and Forge Processes
Copyright © TWI Ltd 2015
Linear Friction Welding
Linear Friction Stir Welding
High quality, automated, quick, self regulated, self cleaning, repeatable welding process
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Fast: typically under 30s cycle time Accurate: positioning under 0.10mm and reproducible: under 0.25mm
Copyright © TWI Ltd 2015
Preserves a hot forged microstructure
Thin heat affected zone Recrystallised
to fine grained equiaxed microstructure at weld centre
Can be post weld heat treated for performance
Near-parent tensile and fatigue properties can be achieved
LFW: High Quality Weld in Ti Alloys
↑ Ti-6Al-4V ↓
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LFW PWHT Parent Metal Preserves a hot forged microstructure
Thin heat affected zone Recrystallised
to fine grained equiaxed microstructure at weld centre
Can be post weld heat treated for performance
Near-parent tensile and fatigue properties can be achieved
LFW: High Quality Weld in Ti Alloys
Both components fractured in the parent metal
Copyright © TWI Ltd 2015
Critical aero engine component: compressor rotor
Mature production: fighters engines Power to Weight ratio Performance
Uptake: large civil engines
Fuel saving Environmental regulations
In-house knowledge and qualification
LFW current products: Blisks
Courtesy of GE
Courtesy of EuroJet
Courtesy of Rolls-Royce
Copyright © TWI Ltd 2015
LFW
Understand
Explore
Demonstrate
Transfer
Implement
Qualify
Friction and Forge Processes activities
Copyright © TWI Ltd 2015
LFW
Understand
Explore
Demonstrate
Transfer
Implement
Qualify
Friction and Forge Processes activities
Copyright © TWI Ltd 2015
Analysis of LFW cycles: current work
Independent monitoring of LFW cycles Helps the LFW Process Engineer in making his/her
decision
Offer evidence to support the welding operation Unobtrusive addition of sensors High sampling rate
Open, adaptable tools Individual weld cycles (QC) Series repeatability
Project should be transferable toother machines in the future
Copyright © TWI Ltd 2015
Anthony McAndrewContaminant Removal in Ti6Al4V 1st publication: 2013 2nd publication: 2014 Thesis: 2015
Lucie LeeNovel Industrial Applications 1st publication: 2016 2nd publication: 2017 Thesis: 2018
Modelling of LFW
Copyright © TWI Ltd 2015
LFW
Understand
Explore
Demonstrate
Transfer
Implement
Qualify
Friction and Forge Processes activities
Copyright © TWI Ltd 2015
Demonstrating capabilities of LFW
Like for like performance
New design freedoms
Core Research
Smart manufacture