September 17, 2014 [email protected]
7th INTERNATIONAL EWI/TWI SEMINAR ON
JOINING AEROSPACE MATERIALS
CHARACTERIZATION OF
THE ULTRASONIC STIR WELDING (USW) PROCESS
Jeff Ding
Materials and Processes Laboratory
Marshall Space Flight Center
Huntsville, Alabama
September 17, 2014 [email protected]
AGENDA
• Process description
• Chronology of USW
• Current USW system and capabilities
• Current process development/test
results
• Future work
• Conclusions
September 17, 2014 [email protected]
• A solid state weld process consisting of an induction coil heating
source, a stir rod, and a non-rotating containment plate
• High Power Ultrasonic (HPU) energy integrated into non-rotating
containment plate and stir rod
• Independent control of heating, stirring and forging pressure
control
• NASA owned IP - U.S. Patents
• 7,568,608 “USW Process and Apparatus”
• 8,393,520 “Pulsed Ultrasonic System”
• 8,393,523 “Pulsed Ultrasonic Method”
WHAT IS USW?
September 17, 2014 [email protected]
USW: Only the stir rod rotates Containment plate stationary Induction coil heats the material Additional heat is provided by material deformation around the pin Ultrasonic energy integrated into stir rod and CP DECOUPLE heating, stirring,forging and Control each independently
FSW: Both shoulder and pin rotate together Material is heated by frictional energy & deformational heating around pin Cannot decouple heating, stirring, forging
WORKPIECE
shoulder
pIn
ANVIL
ANVIL
WORKPIECE
CONTAINMENT PLATE
STIR ROD ROD ROTATION
ULTRASONIC
TRANSDUCER
STIR ROD
ULTRASONIC
TRANSDUCER
ULTRASONIC TRANSFER BAR
induction coil
downward force/rotation
downward
force
PROCESS DESCRIPTION
September 17, 2014 [email protected]
Bearings
Saddle Plate
Lock Nut
Location Screw
Containment Plate
Ultrasonics - Containment
Transducer Transmission Line
Containment – A-2 steel
September 17, 2014 [email protected]
Transducer Diaphragm
Spring
Booster Diaphragm
Spring
Spindle
Sonotrode
Ultrasonics - Spindle
Stir Rod – 350 marage steel
September 17, 2014 [email protected]
2008 First
Experimentation
at MSFC
Leased EWI twist
drill system
USW PROCESS CHRONOLOGY
FRICTION REDUCTION PLUNGE FORCE REDUCTION
September 17, 2014 [email protected]
USW PROCESS CHRONOLOGY
2009 - Ultrasonic Friction Reduction Test Bed
2010 - High Temperature Tests of Ultrasonic
Friction Reduction
• Bridgeport converted into USW Prototype
System in 2012
September 17, 2014 [email protected]
September 17, 2014 [email protected]
• Ability to “pulse” ultrasonic (US) energy on and off and adjust
parameters real-time (travel speed, spindle RPM, US amplitude, X
and Z axis position, plunge and pin axis force)
• Means to measure draw force.
• Ability to record US power versus time
• Head deflection reduction - two laser height sensors.
• Adding linear encoder to better control tool penetration setting.
• Ultrasonic energy integrated into stir rod and containment plate.
• Maximum 600 RPM.
• Maximum Z force 15,000 pounds.
• Independent control of heating capability via induction technology.
USW SYSTEM CAPABILITIES
September 17, 2014 [email protected]
USW PROCESS ATTRIBUTES
• Decreased plunge forces in Z axis • Decreased frictional forces in X axis • Decreased shear forces in X axis • Increased travel rate • Increased tool life
FIRST WELDS • Conducted only three weeks ago • No induction coil pre-heat • No pulsing of US power • Aluminum 2219 .250-in
September 17, 2014 [email protected]
PLUNGE FORCE CHARACTERIZATION
Procedure: Plunged stir rod travelling .25 IPM varying ultrasonic amplitude
High: 1324 lb. Low: 886 lb. Delta: 33% reduction
September 17, 2014 [email protected]
TEST PANEL 14 Procedure: Plunged stir rod travelling .25 IPM No CP/Spindle US
Travel=4 IPM 350 RPM
Tult = 29.07 ksi
Tyld = 29.04ksi
13-1
14-1
14-8
Tult = 40.81 ksi
Tyld = 29.42ksi
-500
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
0 200 400 600
LO
AD
S (
LB
S)
TIME (SEC)
PROCESS LOADS
XYZ_Force_Feedback
_X
XYZ_Force_Feedback
_Y
XYZ_Force_Feedback
_Z
September 17, 2014 [email protected]
COMPARISON OF
13-1 TO 14-1
13-1
90% Amplitude
14-1
0% Amplitude
September 17, 2014 [email protected]
TEST PANEL 12 EFFECT OF SPINDLE ULTRASONICS ON WELD NUGGET AT DIFFERENT AMPLITUTUDES
Containment Plate Ultrasonics 50% Amplitude
Travel = 4 ipm RPM = 350 RPM
L/2 L/2
SPU=90% SPU=0
September 17, 2014 [email protected]
TEST PANEL 12
12-1
SPU=90%
CPU=50%
12-4
SPU=0
CPU=50%
Tult = 41.82 ksi
Tyld = 28.67ksi
Tult = 44.75 ksi
Tyld = 30.82ksi
-500
0
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
1
48
4
96
7
14
50
19
33
24
16
28
99
33
82
38
65
43
48
48
31
53
14
57
97
62
80
67
63
72
46
77
29
82
12
86
95
XYZ_Force_Feedback_X
XYZ_Force_Feedback_Y
XYZ_Force_Feedback_Z
September 17, 2014 [email protected]
L/5 L/5 L/5 L/5 L/5
90% A 80% A 70% A 60% A 50% A
TEST PANEL 13
Tult = 46.65 ksi
Tyld = 31.16 ksi
Tult = 42.40ksi
Tyld = 3 2.49 ksi Tult = 45.88 ksi
Tyld = 33.54 ksi
Tult = 33.91 ksi
Tyld = 31.12 ksi
September 17, 2014 [email protected]
FUTURE WORK
• Address penetration issue
• Begin induction coil pre-heat
• Characteristics of hot weld versus cold weld
• Pulse ultrasonics on/off
• Determine upper limit of CP amplitude
• Faster travel rates
• Develop parameters for heat resistant alloys
September 17, 2014 [email protected]
Technology Transfer Office
Sammy Nabors – 256-544-5226
TECHNOLOGY LICENSING
OPPORTUNITIES
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