Esab. Technical Handbook. Friction Stir Welding

Technical Handbook Friction Stir Welding Contents page Introduction 4 page Equipment 37 Full-scale automation for Process principles 6 high-volume applications 37 Weldable alloys 6 Modular flexibility for Process characteristics 7 “standard” applications 37 Welding parameters 7 Robotised for more complex applications 37 Tools 7 Design principles 8 Tools for steels 8 Retractable pin tool 8 Quality and enviromental aspects 39 Environmental aspects of Friction Stir Welding 39 Bobbin tool 10 Less weld-seam preparation 39 Process speed 10 Fewer resources 39 Aluminium 13 Noise, an underestimated health threat 39 Energy saving FSW process 39 Application areas Aerospace 15 15 Less post-treatment and impact on the environment Space industry 15 Friction Stir Welded components offer Civil aviation 16 through-life environmental gains Aerospace R&D 16 Quality 40 39 40 Shipbuilding 18 Application advances 18 Parts and components 19 Economics Example of cost analysis 41 42 Automotive industry 21 Compared to arc welding 44 Automotive applications 22 Tailor welded blanks (TWB´s) 27 Conclusions 46 Superplastic forming 27 Extruders and extrusions – with special focus on rolling-stock panels 28 Steel and other high-temperature materials 30 Application examples 32 Case study: Swedish Nuclear 32 Case study: Marine Aluminium a.s, Norway 35 DISCLAIMER Whilst all reasonable efforts have been made to ensure the accuracy of the information contained in this handbook at the time of going to press, ESAB gives no warranty with regard to its accuracy or completeness. It is the responsibility of the reader to check the accuracy of the information contained in this handbook, read product labels and equipment instructions and comply with current regulations. If the reader is in any doubt with regard to the proper use of any technology they should contact the manufacturer or obtain alternative expert advice. ESAB accepts no responsibility or liability for any injury, loss or damage incurred as a result of any use or reliance upon the information contained in this handbook. 3 Introduction to the FSW Technical Handbook Friction Stir Welding (FSW) was invented by Wayne transferred to the trailing edge of the tool pin, is Thomas at TWI (The Welding Institute), and the first forged through intimate contact with the tool patent applications were filed in the UK in December shoulder and pin profile. On cooling, a solid