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.
INDEX About Kawasaki Back ground of LFW development LFW test @TWI Welding conditions Macro structures Mechanical properties Further development program Conclusion 2
About Kawasaki Opening up new possibilities for customers and community at large 3
History of Kawasaki 1878 Shozo Kawasaki, the founder opens Kawasaki Tsukiji Shipyard (Tokyo). 1902 Finishes construction on Dry Dock at Kobe Shipyard. 1926 Constructs Eitaibashi Bridge, Tokyo. 1941 Starts production of Hien fighter. 1975 Unveils Z1 motorcycle. 1976 Develops GPS200 gas turbine generator. 1981 Delivers the first LNG carrier built in Japan. 1996 2001 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. 2004 Ships first 700T train to Taiwan High Speed Rail 4
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
One Kawasaki Land. Sea. Air. worldwide 6
INDEX About Kawasaki Back ground of LFW development LFW test @TWI Welding conditions Macro structures Mechanical properties Further development program Conclusion 7
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
INDEX About Kawasaki Back ground of LFW development LFW test @TWI Welding conditions Macro structures Mechanical properties Further development program Conclusion 9
LFW test -Welding condition- Make Joints by various welding condition to understand LFW process Welding parameter Friction and forge pressure : 30-150MPa 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 E20 @TWI Frequency Amplitude Speed Pressure (Hz) (mm) (mm/s) (MPa) 40 2.0 503 90 20 1.0 126 60 20 1.0 126 90 40 1.0 251 30 40 2.0 503 30 40 2.0 503 150 50 2.5 785 30 50 2.5 785 90 50 2.5 785 150 10
LFW test @Ti-64 - 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
LFW test @Ti-64 - 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
Friction Speed LFW test @Ti-64 - 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
Speed(mm/s, f*a*2π) Speed(mm/s, f*a*2π) Speed(mm/s, f*a*2π) LFW test @Ti-64 - Break position - 1000 900 800 700 600 500 400 300 200 100 0 1000 900 800 700 600 500 400 300 200 100 0 Burn off : 2mm Position TS3 0 50 100 150 200 Burn off : 2mm Position TS1 Pressure(MPa) 0 50 100 150 200 Pressure(MPa) TS3 Interface Mix Base metal TS1 Interface Mix Base metal LFW has large process window for Ti alloy. 1000 900 800 700 600 500 400 300 200 100 0 Burn off : 2mm Position TS2 TS1 TS3 Position of specimen picked 0 50 100 150 200 Pressure(MPa) TS2 Interface Mix Base metal TS2 Oscillate Direction 14
Tensile strength (MPa) Elongation (%) Tensile strength (MPa) Elongation (%) LFW test @Ti-64 - Tensile strength - 1150 1100 1050 1000 Pressure @90MPa ST TS1 ST TS2 ST TS3 EL TS1 EL TS2 EL TS3 Parent UTS 40 35 30 25 1150 1100 1050 1000 @40Hz 2mm ST TS1 ST TS2 ST TS3 EL TS1 EL TS2 EL TS3 Parent UTS 40 35 30 25 950 20 950 20 900 15 900 15 850 10 850 10 800 5 800 5 750 1mm 1mm 1.5mm 2mm 2.5mm 0 750 30MPa 90MPa 150MPa 0 20Hz 40Hz 50Hz 40Hz 50Hz Pressure Friction condition LFW has Good property. TS3 TS1 TS2 Oscillate Direction 15
INDEX About Kawasaki Back ground of LFW development LFW test @TWI Welding conditions Macro structures Mechanical properties Further development program Conclusion 16
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
INDEX About Kawasaki Back ground of LFW development LFW test @TWI Welding conditions Macro structures Mechanical properties Further development program Conclusion 18
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
20