Refill Friction Spot Joining - ewi.org KHI_OKADA · PDF file7th International EWI/TWI...

Refill Friction Spot Joining

Hideki Okada

Kawasaki Heavy Industries, Ltd., Japan

7th International EWI/TWI Seminar on

Joining Aerospace Materials

September 17, 2014 – September 18, 2014

© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved 2

INDEX

1.Introduction

2.Process and features of FSJ

3.Evaluation of Joint properties

4. Actual prototype trial

5.Conclusion


1.Introduction

About us, Kawasaki Heavy Industries,LTD.


1.Introduction

Rivet

FSJ attracts attention in Aerospace Industry to replace

riveting technology.

ＦＳＪ

Competitive edge in techniques

Competitive edge in costs

Competitive edge in geoenvironmental impact and working environment

High flexibility in designing (e.g. FSJ spacing can be closer together)

Lighter weight than rivets

Low electric consumption

Very little noise and vibration.

High productivity of FSJ leads to cost reduction.

( No need to preprocessing such as drilling, deburring)

Reduction in materials cost (elimination of rivets)

What is the future of aviation fastening


1.Introduction

FSJ in Automotive industry

Exit-hole

Flash

Hook

Thin section

Source : Mazda HP


Plunging Holding

Probe-Plunging

Refill FSJ process and advantages

+Advantageous low plunging force

+Easy to understand, similar to basic FSJ or FSW

-Poor mechanical tensile strength

Plunging

Holding

Shoulder-Plunging

2.Process and features of Refill FSJ

+Excellent tensile strength

-Requires more plunging force and

rigidity of equipment

-Material flow/Welding condition etc. are

far from basic FSJ



Cut model animation of shoulder plunging process



3 servo motors in refill FSJ gun provides tools rotation, shoulder and probe motions independently.

Refill FSJ gun has high Z force (up to 14.7kN) and can join up to t4mm(Upper-sheet) of aluminum alloy and some other materials.

Refill FSJ systems developed by KHI



1) Al2024C-T3 .032InT

evaluation of material lot 2) Al2024C-T3 Alodine

coated material

evaluation of ED,

fatigue etc.

3) Within sealant material



1) Al2024C-T3 evaluation of material lot

Material Thickness SpecificationUpper sheet Al2024C-T3 .032 inch(0.81mm) AMS-QQ-A-250/5Lower sheet Al2024C-T3 .032 inch(0.81mm) AMS-QQ-A-250/5

Joint Method

material conbination

N Max Min Avg. S.D

FSJ

Lot1-Lot1 10 3954 2925 3443 323

Lot1-Lot2 10 3896 3362 3539 166

Lot1-Lot3 10 3845 3375 3609 177

Lot2-Lot1 10 4314 3305 3692 323

Lot2-Lot2 10 4163 2768 3532 436

Lot2-Lot3 10 3711 3075 3502 187

Lot3-Lot1 10 4023 3243 3576 226

Lot3-Lot2 10 3939 3441 3693 165

Lot3-Lot3 10 3688 3308 3482 112

All 90 4314 2768 3563 257

C.V(%) 7.20

A value 2868

RSW (MMPDS) 925

3/32" Rivet (MMPSD) 791

Calculated “A” value based on MMPDS is over 2.8kN and this is higher than that of RSW and Rivet joining

C.V. (Coefficient of Variation) = S.D. / Average *100

0500

100015002000250030003500400045005000

Ten

sile

sh

ear

Stre

ngt

h (

N)

Material combinations



0

500

1000

1500

2000

2500

3000

3500

1) Relationship between thickness and tensile shear strength

Thickness of upper sheet [inch]

Shea

r str

ength

[N

]

0.020 0.025 0.032 0.040

0.020”

0.025”

0.032”

0.040”

Thickness of lower

shetet

0.020”/0.020”

0.020”/0.025”

0.020”/0.032”

0.020”/0.040”

0.025”/0.020”

0.025”/0.025”

0.025”/0.032”

0.025”/0.040”

0.032”/0.025”

0.032”/0.032”

0.032”/0.040”

0.040”/0.032”

0.040”/0.040”

Thickness of

upper sheet[inch]

Thickness of

lower sheet[inch]0.020 0.025 0.032 0.040 0.020 0.025 0.032 0.040 0.025 0.032 0.040 0.032 0.040

Number 10 10 10 10 10 10 10 10 10 10 10 10 10

Max [N] 2101 1890 2205 2600 1705 2090 2231 2355 2202 2741 2345 2851 3117

Min [N] 1433 1568 1744 2055 1317 1578 1964 2178 1680 2323 2140 2394 2702

Average [N] 1854 1787 1929 2277 1548 1880 2082 2281 1973 2560 2249 2611 2960

0.020 0.025 0.0400.032

2) Al2024C-T3 Alodine #1200 coated

The strength tends to increase with increasing the thickness of upper and lower sheets.



0

500

1000

1500

2000

2500

3000

3500ED

Shea

r str

ength

[N

]

Thickness [mm]

Thickness of

upper sheet[inch]

Thickness of

lower sheet[inch]

ED [mm] 6 8 10 12.5 6 8 10 12.5 6 8 10 12.5

Number 10 10 10 10 10 10 10 10 10 10 10

Max [N] 1672 2064 2205 2276 2276 2599 2640 2879 2985 3095 3007

Min [N] 1167 1740 1860 1588 2115 2364 2470 2416 2739 2783 2919

Average [N] 1504 1930 1993 2037 2189 2464 2560 2636 2877 2966 2954

0.020 0.032 0.040

0.020 0.032 0.040

0.020”/0.020” 0.032”/0.032” 0.040”/0.040”

ED=6

ED=8

ED=10

ED=12.5

ED

=6

ED

=8

ED

=1

0

ED

=1

2.5

ED

=6

ED

=10

ED

=1

2.5

ED

=6

ED

=8

ED

=1

0

ED

=12

.5

2) Relationship between E.D. and tensile shear strength


The strength almost saturates over 8mm Edge Distance(1.4 D)



Pitch

72mm

Thickness of

upper sheet[inch]

Thickness of

lower sheet[inch]

Pitch [mm] 6 10 20 24 6 10 20 24 6 10 20 24

Number 10 10 10 10 10 10 10 10 10 10 10 10

Max [N] 4420 5363 6057 6563 5869 7608 8323 8182 5946 7666 8712 8911

Min [N] 3977 4807 5047 4673 4971 7126 7679 7656 5493 6997 8078 8461

Average [N] 4141 5049 5543 5610 5392 7317 8057 7922 5757 7391 8520 8636

0.020 0.032 0.040

0.020 0.032 0.040

0

2000

4000

6000

8000

10000

She

ar

str

eng

th [

N]

0.020”/0.020” 0.032”/0.032” 0.040”/0.040”

Pitch=6

Pitch=10

Pitch=20

Pitch=24

Pitch

=6

Pitch

=1

0

Pitch

=2

0

Pitch

=2

4

Pitch

=6

Pitch

=1

0

Pitch=

20

Pitch

=2

4

Pitch

=6

Pitch

=1

0

Pitch

=2

0

Pitch

=2

4

3) Relationship between Joint pitch and tensile shear strength




Number of Cycles

Parc

ent

of sta

tic s

trength

of

join

t (%

)

0.040”/0.020”

0.040”/0.025”

0.040”/0.032”

0.040”/0.040”

Spot Welding Joint (MMPDS)

125

25

25

12.5

Thickness

[inch]

0.020

/0.040

0.025

/0.040

0.032

/0.040

0.040

/0.040Rifill FSJ [N]

(Average)2277 2281 2249 2960

RSW [N]

(MMPDS)498 658 925 1228

4) Joint lap fatigue test(unguided)




Clad material

Disappearance of interface

Φ 6.11mm ＝ SZ

Al Cu

Cr O

Upper sheet

Al2024C-T3

Lower sheet

Al2024C-T3

2) Al2024C-T3 Alodine #1200 coated 5) Cross section and EPMA analysis

Scattered chrome and oxygen were observed in the clad material., but enough mixing and dividing by mechanical stirring



Aｌ Cu

Upper sheet

Al2024C-T3

Lower sheet

Al2024C-T3

50mm

450mm

750mm 950mm

2) Al2024C-T3 Alodine #1200 coated 6) Tomographic EPMA analysis

Clad material was observed all circumferences of stir zone.



Exposure time：168Hr

Al2024-T3

0.020”

Salt spray

Al6061-T6

0.025”

Apply Sealant

before FSJ

Outside surface

Interfacial surface

Outside surface: Uncorroded

Interfacial surface: Corroded

Outside surface: Uncorroded

Interfacial surface: Uncorroded

3) To improve corrosion resistance, joint within Sealant

1) Corrosion test of Alodine #1200 coated material



With

Sealant

No

Sealant

Number 15 3

Min [N] 2070 2229

Max [N] 2383 2352

Average [N] 2211 2297

A6061-T6

A2024C-T3

With sealant

(Unetched)

A6061-T6

A2024C-T3

No sealant

(Etched)

3) To improve corrosion resistance, joint within Sealant

2) Cross section of joint and of Tensile shear test with Alodine #1200 coated material

Tensile shear strength is almost same. There is black point caused by the sealant in some sealant specimens.


1) Access Panel 2) Frame component

for Helicopter

3) Skin-Stringer-Frame




1) Access Panel

Material ThicknessOuter Skin Al2024C-T42 .032 inch(0.81mm)Inner Skin Al2024C-T42 .032 inch(0.81mm)Small crip Al2024C-T3 .032 inch(0.81mm)

Parts before joining

Outside view of joined panel

Inside view of joined panel



with Alodine#1200

ConbinationRefill FSJ

Joint lap shear strength(N)WEB-DOUBLER 2322

WEB-CAP 2121WEB-DOUBLER-CAP 3977

2) Frame component



2) Frame component

Riveted Frame(as reference)

Refill-FSJed Frame



With Anodize Faying sealant at the interface

3) Skin-Stringer-Frame



3) Skin-Stringer-Frame(Close up picture)



3) Skin-Stringer-Frame (1st Trial movie)


5.Conclusion

Refill FSJ Joint lap shear strength is impressive in

comparison to RSW and riveting.Even though Alodine,

Chromic Acid Anodize material, and with faying sealant

material.

Newly developed refill FSJ robot system can join aircraft

trial parts successfully. This technology has a potential

to produce parts at a high rate with high quality.


Thank you for your kind attention

[email protected]

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Refill Friction Spot Joining - ewi.org KHI_OKADA · PDF file7th International EWI/TWI...

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