Overview of current KHI LFW development program

Transcription

1 3 rd International Linear Friction Welding LFW Seminar 2015 Overview of current KHI LFW development program 19th/March/2015 Hironori Okauchi Manufacturing Technology Department System Technology Development Center Corporate Technology Division Kawasaki Heavy industries, Ltd.

2 INDEX About Kawasaki Back ground of LFW development LFW Welding conditions Macro structures Mechanical properties Further development program Conclusion 2

3 About Kawasaki Opening up new possibilities for customers and community at large 3

4 History of Kawasaki 1878 Shozo Kawasaki, the founder opens Kawasaki Tsukiji Shipyard (Tokyo) Finishes construction on Dry Dock at Kobe Shipyard Constructs Eitaibashi Bridge, Tokyo Starts production of Hien fighter Unveils Z1 motorcycle Develops GPS200 gas turbine generator Delivers the first LNG carrier built in Japan Excavation on the Tokyo Bay Aqua-line is completed by the world's largest shield machines Opens state-of-the-art, fully integrated rolling stock factory unique in the U.S Ships first 700T train to Taiwan High Speed Rail 4

5 Net Sales Business Segment(Year ended March 31,2014) Precision Machinery 8.8% Others 9.9% Ship & Offshore Stracture 5.8% Rolling Stock 10.6% 1,385 billion Aerospace 20.2% Motorcycle & Engine 23.2% Plant & Infrastructure Engineering 7.4% Gas Turbines & Machinery 13.6% 5

6 One Kawasaki Land. Sea. Air. worldwide 6

7 INDEX About Kawasaki Back ground of LFW development LFW Welding conditions Macro structures Mechanical properties Further development program Conclusion 7

8 Back ground of LFW development Advantage of LFW High quality of joints Improvement of Buy to Fly Ratio Machined from solid Environment of LFW LFW equipment for development and production are available However these equipment is too expensive LFW projects in some fabricators were launched Target of KHI s development Material : Ti alloy expensive, difficult to fabricate Studies of Ti alloy LFW were reported Start trail of welding test and evaluation of the joints for internal data LFW 8

9 INDEX About Kawasaki Back ground of LFW development LFW Welding conditions Macro structures Mechanical properties Further development program Conclusion 9

10 LFW test -Welding condition- Make Joints by various welding condition to understand LFW process Welding parameter Friction and forge pressure : MPa Frequency : 20-50Hz Amplitude : ±1 - ±2.5mm Burn-off :2mm (constant) Oscillate direction :Longitudinal (constant) Material :Ti-64, Ti-6246, Dissimilar Amplitude Pressure LFW process Forge Displacement Time Welding condition Frequency Amplitude Speed Pressure (Hz) (mm) (mm/s) (MPa)

11 LFW - Appearance of LFW joint - Frequency : 40Hz Amplitude : 2mm Pressure : 30MPa Frequency : 40Hz Amplitude : 2mm Pressure : 90MPa Frequency : 40Hz Amplitude : 2mm Pressure : 150MPa As a pressure increases flash becomes sharp and thin. 11

12 LFW - Appearance of LFW joint - Frequency : 20Hz Amplitude : 1mm Pressure : 90MPa Frequency : 40Hz Amplitude : 2mm Pressure : 90MPa Frequency : 50Hz Amplitude : 2.5mm Pressure : 90MPa As frequency and amplitude increase flash becomes sharp and thin. 12

13 Friction Speed LFW - Macro structure - 30MPa 90MPa 150MPa 785mm/s (50Hz- 2.5mm) 503mm/s (40Hz- 2.0mm) 251mm/s (40Hz- 1.0mm) - 126mm/s (20Hz- 1.0mm) - - As pressure and friction speed increase HAZ and TMAZ became thin. 13

14 Speed(mm/s, f*a*2π) Speed(mm/s, f*a*2π) Speed(mm/s, f*a*2π) LFW - Break position Burn off : 2mm Position TS Burn off : 2mm Position TS1 Pressure(MPa) Pressure(MPa) TS3 Interface Mix Base metal TS1 Interface Mix Base metal LFW has large process window for Ti alloy Burn off : 2mm Position TS2 TS1 TS3 Position of specimen picked Pressure(MPa) TS2 Interface Mix Base metal TS2 Oscillate Direction 14

15 Tensile strength (MPa) Elongation (%) Tensile strength (MPa) Elongation (%) LFW - Tensile strength ST TS1 ST TS2 ST TS3 EL TS1 EL TS2 EL TS3 Parent UTS mm ST TS1 ST TS2 ST TS3 EL TS1 EL TS2 EL TS3 Parent UTS mm 1mm 1.5mm 2mm 2.5mm MPa 90MPa 150MPa 0 20Hz 40Hz 50Hz 40Hz 50Hz Pressure Friction condition LFW has Good property. TS3 TS1 TS2 Oscillate Direction 15

16 INDEX About Kawasaki Back ground of LFW development LFW Welding conditions Macro structures Mechanical properties Further development program Conclusion 16

17 Further development program Problem for production Method of quality control for LFW joints Only in process monitoring? Different from Aero space to other industries? Capital cost for LFW equipment Too expensive 17

18 INDEX About Kawasaki Back ground of LFW development LFW Welding conditions Macro structures Mechanical properties Further development program Conclusion 18

19 Conclusion KHI have made various products since established. KHI started LFW project because we found advantage of LFW. KHI found that LFW joint of Ti alloy had good properties and large process window. KHI will continue this project to apply LFW to production. 19

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