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Since there is no section for FSW, I am putting this here. A moderator can put it where ever they see fit.This is Convention Friction Stir Welding of 2219 T851, 1.250.These are the 6"X24" slabs that will be welded. They are pre-weld prepared with scotch brite on the crown and root sides and filed on the faying surfaces.Here the slabs are fitted and clamped in the weld tool. It can handle 22' long panels and i have welded the last two Space Huttle External Tank barrels ever to be manufactured in this tool. The adaptor that nated orion to the Delta IV rocket that launced recently was welded on this tool as well.This is the initial tack tool with a .050 nib and the weld tool that does the finished weld.This is the 2nd pass tack tool. This thick stuff takes two tacks to hold it together with that aggressive final weld tool.Two turn tables and a microphone.
Reply:Tacking initial tack.Skipped 2nd pass because you can't tell it from the first in a picture anyway.Drilled start hole for final weld pass. you have to do this because the big tool displaces so much metal that it is hard to plow through all of that and get a good weld start.Aligning weld tool in start hole.Post weld 'tombstone" laying on work table.Two turn tables and a microphone.
Reply:There is about .015 between the tip of the weld tool and the backing anvil when it's being welded. That dimension is referred to as the "ligament".Two turn tables and a microphone.
Reply:This is what happens when the tool has a spontaneous run away. It takes a lot of force to break that MP159 pin.Two turn tables and a microphone.
Reply:Can you friction stir disimilar metals ? I thought I read some place that you could . but It may have been a different process.
Reply:Originally Posted by gxbxcCan you friction stir disimilar metals ? I thought I read some place that you could . but It may have been a different process.
Reply:Sorry but am I to understand that the space shuttle main tank was made of 4" thick aluminum?
Reply:Originally Posted by atgSorry but am I to understand that the space shuttle main tank was made of 4" thick aluminum?
Reply:Notice how the 2 plates aren't warped and bent up in the finished weld picture?that's because FSW doesn't enter the metal into a liquid phase... since it doesn't change phase and remains plastic, there is no thermal contraction upon re-solidification as with other types of welding.Last edited by MikeGyver; 12-22-2014 at 01:43 AM.Welding/Fab Pics: www.UtahWeld.com
Reply:"Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:That's really cool. I notice the tooling leaves a massive crater at the end of the weld... Is it safe to assume the welded assembly is oversize, and that section is removed after welding? Or is it filled in?Give me fuel, give me fire, give me that which I desire.
Reply:Originally Posted by PrimetimeThat's really cool. I notice the tooling leaves a massive crater at the end of the weld... Is it safe to assume the welded assembly is oversize, and that section is removed after welding? Or is it filled in?
Reply:@ Pangea - awesome insight into FSW. Can you give us a sense of the reqd pressures (tons) and feed rates on your aluminum projects? Are you using CBN tooling exclusively?"Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Here's a really awesome video on the process.....Just a couple welders, big hammers, grinders, and torches.Work will free you.Men in dirty jeans built this country, while men in clean suits have destroyed it. Trump/Carson 2016-2024
Reply:Originally Posted by ManoKai@ Pangea - awesome insight into FSW. Can you give us a sense of the reqd pressures (tons) and feed rates on your aluminum projects? Are you using CBN tooling exclusively?
Reply:CBN = Cubic Boron Nitride. a ceramic almost as hard as diamond. used in lots of high production machining.But I read in one of the previous posts that the tooling here is a Ni-Co alloy, right?Benson's Mobile Welding - Dayton, OH metro area - AWS Certified Welding Inspector
Reply:Originally Posted by PrimetimeThat's really cool. I notice the tooling leaves a massive crater at the end of the weld... Is it safe to assume the welded assembly is oversize, and that section is removed after welding? Or is it filled in?
Reply:We have been working on a retractable weld pin that will plunge independently from the crown shoulder so that you can taper in on the fly and taper out as well. For circumferential welds it will make for a better termination than the current ragged hole left by the Self Reacting Friction stir process.Two turn tables and a microphone.
Reply:@ Pangae - amazing loads and pressures. Currently physics won't support a suitcase version of this process a la an LN-25 for MIG. Ha! Thx bro.@ AK - cool vid! In the early 2000s, I worked up a proposal with a TWI partner to employ a FSW for underwater rescue applications. The proof of concept was slick, but the project never advanced.@ A_DAB_will_do - you are correct with the Co-Ni-Cr (MP159) alloy. I missed that. The compressive strength of the multi-phase materials rivals CBN. The "195" has a UTS of 205ksi at 1100 def F. Wicked. Check out the tech data from SPS Tech, http://www.spstech.com/web/user_cont...y_brochure.pdf "Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Mano, it's cool you found that video, I have friends that work/worked for MTI/Adams Engineering in South Bend.
Reply:@ vwguy3 - you're not too far from MTI. You should rip a tour, in you haven't already. Would love to see the FSW gear in action. "Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Cool to see NASA use'n BLUE gear......"Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:Originally Posted by gxbxcCan you friction stir disimilar metals ? |
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发表于 2021-8-31 22:08:20