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Professor Stewart Williams Director Welding Engineering and Laser Processing Centre
Presentation overview
Weld metal engineering for 2024 alloy
Requirement for crack free welding Microstructural modelling of optimal compositions Production of crack free welds in 2024 alloy
1st gen.
7020T651 5083H131
20
40
60
80
700 650
V50 (ms-1)
Frag
Solution Combine modern developments in materials modelling with technological welding advances to provide a quick and cost effective method of defining near optimum weld compositions
0.14
0.12 0.1 0.08
40
20
0.02 0
0
Wt% Mg content for fixed 4.3 Wt% Cu
Large freezing range or small fraction of Eutectic liquid leads to the likelihood of cracking
wt.% Cu
Al
Weld metal engineering using a tandem torch with different wire compositions, sizes and feed rates
5 4 3 2 1 0 parent 2 4 6 8 10 12 14
Measured Distance Across Weld (mm)
Black Binary wire rapidly becomes Cu rich and Mg depleted result is cracking Red Ternary mix stable composition throughout weld result is no cracking
6% Cu Wire
5% Mg Wire
CuSi3 Wire
Fusion Welding Improving Weld Metal Properties Al-7Cu-2Mg 1/2m min spd Three Wires
2319 Wire
160 140 120 100 80
60 40 20 0
Hv
60 40 20
Hv
-8
-6
-4
-2
0 Mix 2024
-10 8
-8 10
-6
Hv
Hv
Experimental setup
Shielding gas 20 l/min pure Argon Clamping system Toggle clamps & bars
Surface condition Surface finishing, ground & not prepared
After
Cu bar
Results
Samples were cut in two different positions to check if penetration and IML thickness were constant along the weld seam. Aluminium
Sample Sample
Steel
Results
Sample
Intermetallic layer
Fe2Al5 FeAl3
20 m
Al
Sample U11 B Welding parameters: Power = 4.0 kW; Interaction time = 3.9 s; Travel speed = 20 cm/min; Spot size = 13 mm
St
500
Microhardness [HV]
400
1.6 mm
Al
300
200
Al
100
0 0 1 2 3 4 5 6 7
Distance [mm]
Sample U11-B Base material - Steel Base material - Aluminium
Results: Intermetallic layer thickness evolution Intermatallic layer thicknes vs Specific point energy (point A)
25
20
15
10
0 9 10 11 12 13 14
Results: Intermetallic layer thickness Intermatallic layer thicknes vs Specific point energy evolution (point A, manually ground)
25
20
15
10
0 9 10 11 12 13 14 15 16
What is Metal Additive Manufacture - Basic Process Programme a robot or machine tool to trace out the layers
Very Simply
Powder based
X Low deposition rates (0.1-0.2 kg/h) X Low material efficiency (10-60%) X Quality and flaw issues X Very high part cost High level of complexity
Wire based
High deposition rates (several kg/h) High material efficiency (90%) No defects Low part cost x Medium to low level of complexity
WAAM Process
WAAM machine
CAD STL
WAAM workpiece
RUAMRob 2.0 Slicing and path generation (within a couple of minutes)
800mm
WAAM - Large parts Variable wall thickness cylinder example satellite launch vehicle part After machining
As deposited 6 hours
Aluminium
Yield 140 MPa, UTS 300 MPa, elongation 12%, failure in bronze
Vertical hardness - Cu to Steel
150
145 140 Vickers Hardness
135
130 125
120
115 110
105
100 -3000 -2000 -1000 0 Distance in 1000 2000 3000
GTAW TORCH
ROLLER
SUBSTRATE
7 6 5
4 3 2
Distortion [mm]
CONTROL 50 kN 75 kN
1 0
Effect on Geometry
Std. Dev.
Control
50 kN
75 kN
Control 50 kN 75 kN 1.13 1.04 0.93 0.19 0.12 0.09
Rolling introduces deformation, nucleation sites and stored energy into the large beta grains, thus inducing recrystallisation when layers are reheated during the subsequent deposition
75 kN
Grain size Primary grains Alpha Lathes length Alpha Lathes Width
75 kN 83 m 7.7 0.7
Installation of large scale ALM facility now complete HiVE (old Airbus FSW machine) HiVE Technology demonstrator system implemented for large scale WAAM incorporating milling, and rolling (to be completed)
Milling cutter
Welding torch
40