Manufacturing of a demonstrator for Linear Welding (LFW) of dissimilar materials

Manufacturing of a demonstrator for Linear Welding (LFW) of dissimilar materials

Case Studies Manufacturing of a demonstrator for Linear Welding (LFW) of dissimilar materials

Manufacturing of a demonstrator for Linear Welding (LFW) of dissimilar materials

“The work performed in this investigation has successfully demonstrated that LFW can be used to join various combinations of metals.”

Rob Gil, MTC


The Primary Focus

The primary focus of this deliverable was the production and evaluation of commercial material welds manufactured by linear friction welding. The structure-property analysis of the MTC samples confirmed that linear friction welding is a feasible and effective technology for the production of high quality welds in short processing times. In this study LFW has been used to join various combinations of metals based on typical industrial requirements. These trials included welds of aluminium alloy 7050, micro-alloy steel, Inconel 718, aluminium alloy 6082, commercially pure copper (C101) and commercially pure aluminium 1050. These materials and their welding order was chosen due to its industrial relevance. The product of this novel research is still being used to highlight the linear friction welding capabilities of the MTC. The main focus of this deliverable was to evaluate the LFW weld quality in terms of assessing the mechanical and metallurgical properties for a range of commercial materials, all included in the demonstrator.

The Process

As the engineer responsible for this work package, I was in charge of its planning (including resourcing), reporting and delivery. I directed the procurement of all material for samples and tooling, design of tooling, machining plan, heat treatment, design of welding and design of parameters (the steering group made comments and suggestions on this). Then, I planned and directed the actual welding, with the help of Chris Burchell and Jian Yang (see below image). I directed the metallurgical studies and property measurements and tooling geometrical measurements (CMM) before and after welding. The analysis of welding (graphs, inspections, energy consumption) was performed by a colleague (Jian Yang) under my supervision. Together we establish the parameter process windows for these materials. The post welding machining (CNC, EDM, Laser engraving) was included and the whole project successfully managed on time and on budget.

The Outcome

The work performed in this investigation has successfully demonstrated that LFW can be used to join various combinations of metals. A range of welding parameters upon each material combination was investigated; these included burn-off, oscillation frequency and amplitude, friction pressure and duration. Welding process windows have been plotted based on successful welds. Structure-property analysis has shown that linear friction welding is a feasible and effective technology for producing high quality welds with a short processing time and very limited material waste.

Structure-property analysis has shown that linear friction welding is a feasible and effective technology for producing high quality welds with a short processing time and very limited material waste

Rob Gil, MTC