Friction Stir Welding for Marine Construction

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Emanuel de Barros Viveiros
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2 Friction Stir Welding for Marine Construction Stephen Cater Friction and Forge Processes Group TWI Ltd, United Kingdom Tel: ,

Group TWI Ltd, United Kingdom Tel: +44 114

3 Friction Stir Welding

4 Advantages of Friction Stir Welding All aluminium grades can be welded Excellent in strength, fatigue, corrosion Very low distortion Automated process and so consistent quality No fumes, no radiation, low noise Single pass process, even for thick sections Cost benefits no filler, no gas, low labour costs

process and so consistent quality No fumes, no radiation, low noise Single

5 FSW in thick aluminium 50mm 75mm

6 Design S-N Curves for AA6005

7 Stress range, MPa Fatigue Results for FSW Butt Welds ECCS Class B welded 7075 plate 2014 welded 2014 plate 2219 welded 2219 plate 5083 welded 5083 plate Endurance, cycles

8 FSW Approvals FSW Bulkhead Panel FSW Deck Panel Lloyds Register DNV Bureau Veritas RINA ABS Germanisher Lloyd TUV DB FAA

9 Explosively formed, FSW Hulls

10 FSW Construction USN Sea Fighter Nichols Bros AJT

11 Current FSW Ships

12 FSW in production

13 Current R&D Improved tool designs Portable, low cost machines FSW of Steel, Titanium FSW of thick section Al (LNG applications) FSW of dissimilar materials FSW for more complex shapes

14 Steel Friction Stir Welding New FSW tool materials from Megastir Inc offer the potential for welds in steel in excess of 50 m in length. TWI has performed multiple welds in 6 mm thick structural steels such as HSLA 65, S355, RQT1 and 304L stainless steel The process produces low distortion

TWI has performed multiple welds in 6 mm thick structural steels such as

15 Friction Stir Welding Steel Friction Stir Weld in 6mm thick HSLA 65 plate. (USN shipbuilding steel) Friction Stir Weld in 6mm thick high strength RQT 701 steel Friction Stir Weld in 6mm thick 304L stainless steel

16 FSW of Titanium 6.35mm Ti-6Al-4V welded at 100mm/min 6.35mm Ti-6Al-4V welded at 200mm/min

17 Friction Stir Lock Aluminium to Steel

18 Conclusions 193 FSW licensees worldwide, 1600 patent applications WPS or component approvals by major classification societies Many commercial applications of Friction Stir Welding in aluminium shipbuilding worldwide The FSW of steel may now be becoming economically viable Process will be used more when its many advantages are fully appreciated by naval architects and designers

aluminium shipbuilding worldwide The FSW of steel may now be becoming economically viable

19 Collaboration In 2010 the EU may call for proposals from SME Associations for collaborative research under the Framework 7 programme. TWI would be pleased to work with consortia of shipbuilding SMEs & naval associations to submit research proposals to further develop friction stir welding for the benefit of the European maritime sector. TWI is holding a demonstration of friction stir welding of steel in the UK, October 13 th 15 th. Invitations to the event are available from TWI.

TWI would be pleased to work with consortia of shipbuilding SMEs & naval associations to submit research proposals to

20 Friction Stir Welding for Marine Construction Stephen Cater Friction and Forge Processes Group TWI Ltd, United Kingdom Tel: ,

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