2014/9/4
Refill Friction Spot Joining
Hideki Okada Kawasaki Heavy Industries, Ltd., Japan
INDEX
1.Introduction 2.Process and features of FSJ 3.Evaluation of Joint properties 4. Actual prototype trial 5.Conclusion © 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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1.Introduction About us, Kawasaki Heavy Industries,LTD.
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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1.Introduction FSJ in Automotive industry
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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1.Introduction What is the future of aviation fastening Rivet ＦＳＪ FSJ attracts attention in Aerospace Industry to replace riveting technology. Competitive edge in techniques High flexibility in designing (e.g. FSJ spacing can be closer together) Lighter weight than rivets Competitive edge in costs High productivity of FSJ leads to cost reduction. ( No need to preprocessing such as drilling, deburring) Reduction in materials cost (elimination of rivets) Competitive edge in geoenvironmental impact and working environment Low electric consumption Very little noise and vibration. © 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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1.Introduction Basic FSJ process and disadvantages for Aircraft Exit-hole Hook
Thin section Flash
Retained water generated by condensation in exit-hole can lead to corrosion Thin section and flash will be a fatigue break point Optimized tool length is required for each plate thickness
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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2.Process and features of Refill FSJ Refill FSJ process and advantages Probe-Plunging
Probe Shoulder Clamp
Plunging Holding
Holding
Work
(1)Clamping and pre-heating
(2)Plunge
Stir zone
(3)Re-plunge
(4)Tool removal
Shoulder-Plunging
Probe Shoulder Clamp
Holding
Holding
Plunging
Work
(1)Clamping and pre-heating
(2)Plunge
(3)Re-plunge
(4)Tool removal
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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2.Process and features of Refill FSJ Refill FSJ process and advantages Probe-Plunging
Plunging Holding
Shoulder-Plunging
Holding
Plunging
Clamping tool encloses the shoulder tool holds work-piece tightly to prevent burring and creates a flat surface. Probe Plunging process looks like basic FSJ. Shoulder plunging process has excellent tensile strength In either case, refill process can make surface flat.
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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2.Process and features of Refill FSJ Cut model animation of shoulder plunging process
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© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
2.Process and features of Refill FSJ Refill FSJ system developed by KHI
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. © 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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3.Evaluation of Joint properties Joint appearance of Al2024C-T3 Alodine #1200 coated Material Thickness Upper sheet Al2024C-T3 .040 inch(1.02mm) Lower sheet Al2024C-T3 .040 inch(1.02mm)
Top side surface
Specification AMS-QQ-A-250/5 AMS-QQ-A-250/5
Back side surface
Joint surface is almost flat No dent on top/back surface Joining time is 3.7s © 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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3.Evaluation of Joint properties Tensile shear test of Al2024C-T3 Alodine #1200 coated Result of tensile shear test Number Min. [N] Refill Max. [N] FSJ Average[N] joint S.D [N] C.V. [％] A value [N] RSW joint [N] （ MMPDS） 1/8' Rivet joint [N] （MMPDS）
30 2702 3117 2960 113 3.82 2614 1228 1374
C.V. (Coefficient of Variation) = S.D. / Average *100
Tensile shear fracture mode almost specimens showed pull out fracture
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0.040int
0.040int
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3.Evaluation of Joint properties Tensile shear test of Al2024C-T3 Alodine #1200 coated Evaluation of Edge Distance ED
ED [mm] Number Min [N] Max [N] Average [N]
6 10 2416 2879 2636
8 10 2739 2985 2877
10 10 2783 3095 2966
12.5 10 2919 3007 2954
Shear strength [N]
4000 3000 2000 1000 0 6
8
10
12.5
ED [mm]
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3.Evaluation of Joint properties Tensile shear test of Al2024C-T3 Alodine #1200 coated Evaluation of Joint pitch Pitch [mm] Number Min [N] Max [N] Average [N]
Pitch 72mm
10 20 24 10 10 10 6997 8078 8461 7666 8712 8911 7391 8520 8636
Shear strength [N]
10000 8000 6000 4000 2000 0 10
20
24
Pitch [mm]
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3.Evaluation of Joint properties Joint lap fatigue test of Al2024C-T3 Alodine #1200 coated Parcent of static strength of joint (%)
Thickness 0.020 0.025 0.032 [inch] /0.040 /0.040 /0.040 Rifill FSJ [N] 2277 2281 2249 (Average) RSW [N] 498 658 925 (MMPDS)
0.040 /0.040 2960 1228
0.040”/0.020” 0.040”/0.025” 0.040”/0.032” 0.040”/0.040” Spot Welding Joint (MMPDS) 12.5 25 25 125
Number of Cycles © 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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3.Evaluation of Joint properties Cross section of Al2024C-T3 Alodine #1200 coated Upper sheet Al2024C-T3 Lower sheet Al2024C-T3
Φ6.11mm ＝ SZ
Disappearance of interface
Al
Cu
Cr
O
Clad material
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3.Evaluation of Joint properties EPMA analysis of Al2024C-T3 Alodine #1200 coated
(1)Clamping and pre-heating
(2)Plunge
(3)Re-plunge
Cr
(4)Tool removal
Cr
Cr disappeared
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3.Evaluation of Joint properties Corrosion test of Al2024C-T3 Alodine #1200 coated Exposure time：168Hr Al6061-T6 0.025”
Salt spray
Apply Sealant before FSJ
Outside surface Al2024-T3 0.020”
Outside surface: Uncorroded Interfacial surface: Corroded Uncorroded Interfacial surface © 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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3.Evaluation of Joint properties To improve corrosion resistance, joint within Sealant Cross section and Tensile shear test of Al6061/Al2024C with sealant With Without Number Min [N] Max [N] Average [N]
A6061-T6
Sealant 15 2070 2383 2211
Sealant 3 2229 2352 2297
Without sealant (Etched)
A2024C-T3
A6061-T6
With sealant (Unetched)
A2024C-T3 19
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
3.Evaluation of Joint properties
Dissimilar joint of Aluminum and steel for Automobile
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
Ti-6Al-4V (1mm + 1mm)
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4. Actual prototype trial 1.Pilot door
Parts Name
Thickness[mm]
Material
Parts Name
Thickness[mm]
Material
INNER SKIN OUTER SKIN DOUBLER ANGLE SPLICE DOUBLER
0.635 0.635 0.8128 0.635 0.635 0.635
6061-T62 6061-T62 2024C-T42 2024C-T42 2024C-T42 2024C-T42
DOUBLER DOUBLER CHAMMEL DOUBLER DOUBLER
0.635 0.635 0.635 0.635 0.635
2024C-T3 2024C-T3 6061-T62 6061-T62 2024C-T42
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4. Actual prototype trial 1.Pilot door
Fixture of this trial © 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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4. Actual prototype trial 1.Pilot door
Joined small parts of this trial
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© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
4. Actual prototype trial 1.Pilot door
Appearance of joined Inner/Outer SKIN © 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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4. Actual prototype trial 1.Pilot door
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© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
4. Actual prototype trial 2.Frame component
Conbination WEB-DOUBLER WEB-CAP WEB-DOUBLER-CAP
Refill FSJ Joint lap shear strength(N) 2322 2121 3977
with Alodine#1200 © 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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4. Actual prototype trial 2.Frame component
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4. Actual prototype trial 3.Skin panel
With Anodize Faying sealant at the interface © 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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4. Actual prototype trial 3.Skin panel (Close-up picture)
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4. Actual prototype trial 3.Skin panel (actual movie)
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5.Conclusion
Refill FSJ joint has a smooth surface without defect, flash and exit hole. 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 with minimal distortion. This technology has a potential to produce parts at a high rate with high quality.
© 2014 Kawasaki Heavy Industries, Ltd. All Rights Reserved
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Thank you for your kind attention
[email protected]
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