WO2022200585A1 - Insert d'outil de soudage par friction-malaxage - Google Patents

Insert d'outil de soudage par friction-malaxage Download PDF

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Publication number
WO2022200585A1
WO2022200585A1 PCT/EP2022/057948 EP2022057948W WO2022200585A1 WO 2022200585 A1 WO2022200585 A1 WO 2022200585A1 EP 2022057948 W EP2022057948 W EP 2022057948W WO 2022200585 A1 WO2022200585 A1 WO 2022200585A1
Authority
WO
WIPO (PCT)
Prior art keywords
tool insert
pin
tool
shoulder surface
stirring pin
Prior art date
Application number
PCT/EP2022/057948
Other languages
English (en)
Inventor
Santonu GHOSH
Teresa Rodriguez Suarez
Stig Andersin
Original Assignee
Element Six (Uk) Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Element Six (Uk) Limited filed Critical Element Six (Uk) Limited
Publication of WO2022200585A1 publication Critical patent/WO2022200585A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/12—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding
    • B23K20/122—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding
    • B23K20/1245—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating the heat being generated by friction; Friction welding using a non-consumable tool, e.g. friction stir welding characterised by the apparatus
    • B23K20/1255—Tools therefor, e.g. characterised by the shape of the probe
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys

Definitions

  • This disclosure relates to a friction stir welding (FSW) tool insert.
  • FSW friction stir welding
  • FSW tool insert for friction stir welding high temperature ferrous alloys and other high temperature alloys.
  • FSW tool assembly in which the tool insert comprises polycrystalline cubic boron nitride (PCBN).
  • FSW is a technique whereby a rotating tool is brought into forcible contact with two adjacent workpieces to be joined and the rotation of the tool creates frictional and viscous heating of the workpieces. Extensive deformation as mixing occurs along a plastic zone. Upon cooling of the plastic zone, the workpieces are joined along a welding joint. Since the workpiece remains in the solid phase, this process is technically a forging process rather than a welding process, none the less by convention, it is referred to as welding or friction stir welding and that convention is followed here.
  • the whole tool/tool holder can be a single piece of shaped tool steel, in which case it is often referred to as a ‘probe’ .
  • the tool is often in two or more parts, with an end element that is in direct contact with the material being welded, often referred to as a ‘puck’ or ‘tool insert’, and the remainder of the tool being the ‘tool holder’ which holds the puck securely and which fits into the FSW machine, so that the tool puck and tool holder together make up the ‘tool’ or ‘tool assembly’.
  • the tool puck is typically shaped to form a shoulder and a stirring pin, often with a reverse spiral cut into the surface so that during rotation it pulls metal towards the pin and pushes this down into the hole being formed by the pin.
  • FSW operations comprise a number of steps, for example: a) an insertion step (also known as the plunge step), from the point when the tool comes into contact with the workpieces to the point where the pin is fully embedded up to the shoulder in the heated and softened workpieces, b) a tool traverse, when the tool moves laterally along the line in between the workpieces to be joined, and c) an extraction step, when the tool is lifted or traversed out of the workpieces.
  • an insertion step also known as the plunge step
  • a tool traverse when the tool moves laterally along the line in between the workpieces to be joined
  • an extraction step when the tool is lifted or traversed out of the workpieces.
  • the tool traverse which is the stage primarily forming the weld, is usually performed under constant conditions; typically these conditions are rotational speed, conditions of the plunge, speed of traverse etc.
  • FSW tool inserts must be capable of withstanding high axial forces required as part of the FSW process.
  • tool insert geometries available. However, they do not automatically transfer to materials such as PCBN without issue. It has been demonstrated that PCBN based tool inserts are capable of withstanding the harsh FSW operating environment, where temperatures reach in excess of 1000°C. Also, tool pucks made from PCBN are relatively cost effective and highly durable. Unfortunately, the inventors have found that PCBN tool inserts shaped using known geometries are prone to abrupt failure during use brought about by high stress concentrations experienced at key locations. This reduces tool life and introduces inconsistency, thereby rendering such tools obsolete for welding steel or superalloys.
  • a friction stir welding (FSW) tool insert comprising polycrystalline cubic boron nitride (PCBN) and having a longitudinal axis of rotation about which it rotates during use, the tool insert further comprising a stirring pin and a coaxial shoulder region, wherein the stirring pin has a pin height measured parallel to the longitudinal axis of rotation between a base of the stirring pin and a maximum point of extension of the stirring pin, and wherein the shoulder region has a largest linear dimension measured perpendicularly to the longitudinal axis of rotation, a ratio between the largest linear dimension of the shoulder region and the pin height being less than 4.5.
  • PCBN polycrystalline cubic boron nitride
  • the ratio between the largest linear dimension of the shoulder region and the pin height is important for PCBN tool inserts used in friction stir welding steel and other high temperature alloys.
  • prior art tool inserts used for friction stir welding aluminium workpieces the aluminium flows significantly more easily than steel.
  • those tool inserts require larger shoulder regions in order to retain the softened aluminium in the welding zone.
  • Larger shoulders require higher applied loads, and these cause higher stresses within the tool insert, leading to more tool failures.
  • friction stir welding steel it is possible to reduce the size of the shoulder region. In this way, the applied loads are reduced, and the stresses within the tool insert are consequently much lower, thereby reducing the risk of failure in the PCBN.
  • a friction stir welding (FSW) tool insert for welding plate with a thickness of at least 12 mm
  • the tool insert comprising polycrystalline cubic boron nitride (PCBN) and having a longitudinal axis of rotation about which it rotates during use, the tool insert further comprising a stirring pin and a coaxial shoulder region, wherein the stirring pin has a pin height measured parallel to the longitudinal axis of rotation between a base of the stirring pin and a maximum point of extension of the stirring pin, and wherein the shoulder region has a largest linear dimension measured perpendicularly to the longitudinal axis of rotation, wherein the pin height is within 95% of the thickness of the plate to be welded, and wherein a ratio between the largest linear dimension of the shoulder region and the pin height is less than 4.5.
  • the pin height is at least 11.8 mm.
  • Figure l is a side view of a tool insert in a first embodiment of the invention.
  • Figure 2 is a side view of the tool insert in a second embodiment of the invention
  • Figure 3 is a side view of the tool insert in a third embodiment of the invention
  • Figure 4 is an image taken from Finite Element Analysis software, indicating the maximum principle stresses incurred within a prior art tool insert.
  • Figure 5 is a cross-sectional view through a fourth embodiment of the tool insert
  • Figure 6 is a perspective view of the tool insert in a fifth embodiment of the invention.
  • Figure 7 is a side view of the tool insert of Figure 6;
  • Figure 8 is a perspective view of the tool insert in a sixth embodiment of the invention.
  • Figure 9 is a side view of the tool insert of Figure 8.
  • a first embodiment of a tool insert is indicated generally at 10.
  • the tool insert 10 has a longitudinal axis of rotation 12 about which it rotates during use in the friction stir welding process. Note that this axis of rotation is not an axis of rotational symmetry due to an asymmetric thread pattern machined into the tool insert 10.
  • the tool insert 10 comprises a stirring pin 14, a shoulder region 16 and a body portion 18, all in axial alignment with each other, with the shoulder region 16 being axially intermediate the stirring pin 14 and the body portion 18.
  • the stirring pin 14, shoulder region 16 and body portion 18 are all integrally formed with each other such that the tool insert 10 is one-piece.
  • the tool insert 10 is machined out of a single PCBN block after the block has been sintered in a HPHT press.
  • the stirring pin 14 has a conical profile, tapering outwardly from rounded apex 20 towards circular base 22.
  • the stirring pin 14 comprises an inscribed spiral 24 running from the apex 20 downwards towards the shoulder region 16.
  • the spiral 24 has an arcuate working surface 26. Notably, there is no (vertical) overhang on the spiral 24, when viewed from the side, to facilitate laser shaping from the direction of the apex 20.
  • the shoulder region 16 comprises a shoulder surface 28 that extends from the stirring pin base 22.
  • the shoulder surface 28 extends generally perpendicularly to the longitudinal axis of rotation 12.
  • the shoulder surface 28 comprises optional spiral 30 (also known as ‘scroll’) or concentric annular grooves for engaging with the workpiece during FSW.
  • the shoulder region 16 extends axially downwardly and merges into the body portion 18.
  • the upper body portion 18a is initially cylindrical proximate the shoulder surface 22.
  • the body portion 18 then steps radially outwardly into a cylindrical lower body portion region 18b, which subsequently tapers radially inwardly towards a circular base 32, remote from the shoulder surface 28.
  • the diameter of the body portion base 32 is 18.4 mm.
  • the body portion 18 is adapted to couple with a tool holder, which fits into a FSW machine.
  • the stirring pin 14 has a pin height 34, which is measured parallel to the longitudinal axis of rotation 12 between the stirring pin base 22 and a maximum point of extension of the stirring pin 14.
  • the shoulder region 16 has a largest linear dimension 36 measured perpendicular to the longitudinal axis of rotation. The ratio between the largest linear dimension 36 of the shoulder region 16 and the pin height is less than 4.5.
  • the pin height 34 is measured parallel to the longitudinal axis of rotation between the shoulder region 16 and the rounded apex 20.
  • the pin height 34 is 5.3 mm.
  • the shoulder region 16 has a largest linear dimension 36 (in this case, a diameter) of 20.0 mm. Therefore, the ratio between the largest linear dimension 36 of the shoulder region 16 and the pin height 34 is 3.8.
  • a second embodiment of the tool insert is indicated generally at 50.
  • Tool insert 50 is similar to tool insert 10, and so only the differences are described.
  • the body portion 18 is not stepped.
  • the body portion 18 has the same diameter 36 as the shoulder region 16, and this diameter 36 is uniform throughout the height of the body portion 16.
  • the proportion of tapered body portion 16 to cylindrical body portion 16 is greater than in the first tool insert 10.
  • the diameter of base 32 is 17.0 mm.
  • the pin height 34 is 5.4 mm.
  • the shoulder region 16 has a diameter 36 of 22.8 mm. Therefore, the ratio between the largest linear dimension 36 of the shoulder region 14 and the pin height 34 is 4.2.
  • a third embodiment of the tool insert is indicated generally at 100.
  • the shoulder region 16 slopes downwards, away from stirring pin base 22. More specifically, the shoulder region 16 is arcuate and comprises a convex shoulder surface 102.
  • the shoulder surface 102 has a radius R in the range of 10 to 40 mm. Preferably, the shoulder surface 102 has a radius R in the range of 15 to 35 mm.
  • a circumferentially extending locking groove 104 is provided in an upper region of the body portion 18, proximate the shoulder region 14, to mechanically engage with a locking collar (not shown), as part of a tool holder retention mechanism.
  • the locking groove 104 extends around the entire circumference of the body portion 16. It is important to note however that the locking groove 104 is not essential to the invention and may be omitted.
  • Two segment shaped slots 106 cut into a lower end of the body portion 16.
  • the segment shaped slots 104 are diametrically opposed to each other.
  • the segment shaped slots 106 cooperate with two segment shaped steps within a specially adapted FSW tool holder (not shown) when the tool insert 100 is in position and supported by the tool holder.
  • the anti-rotation mechanism prevents relative rotational movement between the tool insert 100 and the tool holder about the axis of rotation. Again, it is important to note that the anti-rotation mechanism is not essential to the invention and may be omitted.
  • the pin height 34 is 11.8 mm.
  • the shoulder region 16 has a diameter 36 of 36.0 mm. Therefore, the ratio between the largest linear dimension 36 of the shoulder region 16 and the pin height 34 is 3.1. This tool is ideally suited for welding plate with a thickness of 12 mm.
  • a tool insert with a known geometry is indicated generally at 150.
  • maximum principal stresses are incurred in a region 152 of the shoulder region 14.
  • stresses can be catastrophic.
  • the tool geometry may be further adapted. These adaptations are specifically intended for PCBN based tool inserts.
  • the external transition between the shoulder region 16 and the body portion 18 preferably extends in a curved manner.
  • a fillet i.e. an arcuate surface
  • the fillet 200 has a radius of at least 1.0 mm. This fillet 200 reduces stress concentration along the peripheral edge of the shoulder region 14.
  • spirals 30 on the shoulder region 16 preferably have a pitch height 202 (see Figure 1) measured parallel to the longitudinal axis of rotation.
  • the pitch height 202 must be at least 0.2 mm. This helps to extract maximum life from the tool insert since the shoulder region 16 wears much faster than the stirring pin 14 in use.
  • the pitch height 202 is in the range of 0.2 and 0.5 mm.
  • the stirring pin 12 when the stirring pin 12 is generally conical, the stirring pin 12 has a pin angle 204 equivalent to half the internal cone angle.
  • the pin angle must be in the range of 20 to 50 degrees.
  • the pin angle 204 is in the range of 25 to 40 degrees.
  • the pin height 302 is 14.78 mm.
  • the shoulder region has a diameter 304 of 35.0 mm. Therefore, the ratio between the largest linear dimension of the shoulder region and the pin height is 2.36.
  • This tool is suitable for welding plate with a thickness of 12 mm or more since the pin height is greater than the thickness of 12 mm plate. This tool is ideally suited for welding plate with a thickness of 15 mm.
  • a yet further embodiment of the invention is indicated at 400.
  • the pin height 402 is 19.71 mm.
  • the shoulder region has a diameter 404 of 40.0 mm. Therefore, the ratio between the largest linear dimension of the shoulder region and the pin height is 2.02.
  • This tool is suitable for welding plate with a thickness of 12 mm or more since the pin height is greater than the thickness of 12 mm plate. This tool is ideally suited for welding plate with a thickness of 20 mm.
  • the pin height is sized to be within 95% of the thickness of the plate to be welded. More preferably, the pin height is sized to be within 96% of the thickness of the plate to be welded. Yet more preferably, the pin height is sized to be within 97% or 98% of the thickness of the plate to be welded.
  • transitions between the body portion 18 and the shoulder region 16 may extend in a rectilinear manner.
  • the ratio between the largest linear dimension of the shoulder region and the pin height being less than 4.5 applies whether the shoulder surface is planar or arcuate.
  • FSW tool inserts have a circular lateral cross-section
  • other shapes are envisaged as part of this invention.
  • the largest linear dimension would be a straight line between two diametrically opposed sides.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

La présente invention concerne un outil de soudage par friction-malaxage au nitrure de bore cubique polycristallin (PCBN) approprié idéalement pour le soudage de plaque d'une épaisseur d'au moins 12 mm, la broche de malaxage ayant une hauteur de broche mesurée parallèlement à l'axe de rotation longitudinal entre une base de la broche de malaxage et un point d'extension maximal de la broche de malaxage, et la région d'épaulement ayant une dimension linéaire la plus grande mesurée perpendiculairement à l'axe de rotation longitudinal, un rapport entre la dimension linéaire la plus grande de la région d'épaulement et la hauteur de broche étant inférieur à 4,5.
PCT/EP2022/057948 2021-03-26 2022-03-25 Insert d'outil de soudage par friction-malaxage WO2022200585A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB2104259.3 2021-03-26
GBGB2104259.3A GB202104259D0 (en) 2021-03-26 2021-03-26 Friction stir welding tool insert

Publications (1)

Publication Number Publication Date
WO2022200585A1 true WO2022200585A1 (fr) 2022-09-29

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Application Number Title Priority Date Filing Date
PCT/EP2022/057948 WO2022200585A1 (fr) 2021-03-26 2022-03-25 Insert d'outil de soudage par friction-malaxage

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GB (2) GB202104259D0 (fr)
WO (1) WO2022200585A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060289608A1 (en) * 2005-06-10 2006-12-28 Steel Russell J Friction stirring of high softening temperature materials using new surface features on a tool
US20110309131A1 (en) * 2010-06-18 2011-12-22 Battelle Memorial Institute Friction stir welding tool and process for welding dissimilar materials
EP2835209A1 (fr) * 2012-04-06 2015-02-11 JFE Steel Corporation Procédé pour un soudage par friction et agitation d'une feuille d'acier
FR3039443A1 (fr) * 2015-07-28 2017-02-03 Inst De Rech Tech Jules Verne Procede optimise de soudage par friction malaxage

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107962293B (zh) * 2017-12-14 2020-04-14 湘潭大学 高熔点材料搅拌摩擦焊搅拌头的一体化成型方法
GB201819835D0 (en) * 2018-12-05 2019-01-23 Res With Impact Limited A tool assembly for friction stir welding

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20060289608A1 (en) * 2005-06-10 2006-12-28 Steel Russell J Friction stirring of high softening temperature materials using new surface features on a tool
US20110309131A1 (en) * 2010-06-18 2011-12-22 Battelle Memorial Institute Friction stir welding tool and process for welding dissimilar materials
EP2835209A1 (fr) * 2012-04-06 2015-02-11 JFE Steel Corporation Procédé pour un soudage par friction et agitation d'une feuille d'acier
FR3039443A1 (fr) * 2015-07-28 2017-02-03 Inst De Rech Tech Jules Verne Procede optimise de soudage par friction malaxage

Also Published As

Publication number Publication date
GB202104259D0 (en) 2021-05-12
GB202204232D0 (en) 2022-05-11
GB2607671A (en) 2022-12-14

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