FUN HEAD

THE PROJECT : FUN HEAD

 

The project leading to this application has received funding from the Clean Sky 2 Joint Undertaking under the European Union’s Horizon 2020 research and innovation programme under grant agreement No 831833

THE PROJECT : OBJECTIVES

 

Friction Stir Welding (FSW) is a solid-state joining process with significant advantages over conventional fusion welding methods or classic assembly methods such as fasteners joining. The aim of FUN HEAD project is to design and develop a universal head for Friction Stir Welding (FSW) of aluminium alloys in particular series 2xxx and 7xxx. Indeed, FUN HEAD stands for FSW UNiversal HEAD.

This special head will reach the following 6 main objectives:

> Providing integration of the FSW head with most commercially available CNC machines (independently from machine control system).

> The head will be able to automatically adjust the retraction of the pin in and out of the tool shoulder.

> The developed head will integrate a constant welding force control system following the FSW tool axis.

> The proposed solution will have the capacity of butt and lap joining of sheet metal plate having thicknesses of 0.4mm to 3.0 mm.

> The developed head will allow welding of flat and concave-convex geometries (R > 200 mm).

> The head will be able to support temperature measurement tool. This objective is not a project requirement but a consortium add on to strengthen the project ambitions

THE PROJECT : EXPECTED IMPACTS

 

  • ECONOMIC IMPROVEMENTS
  • &
  • COMPETITIVENESS
  • •Reduction of manufacturing and assembly costs
  • •Possibility of higher automation of joining process
  • •Reduction of investment for FSW technology
  • •Optimization of FSW technologies for structural parts
  • •Integral structure concept
  • IMPROVING INNOVATION CAPACITY
  • &
  • INTEGRATION OF NEW KNOWLEDGE
  • •Universal head means an easier access to FSW technology => new possibilities for design and assembly
  • •Providing performance tables and better knowledge of FSW techniques
  • •Facilitate the implementation of FSW process in aeronautic industries
  • ENVIRONMENTAL IMPACTS
  •  => GREENER AVIATION
  • •Weight saving & drag coefficient reduction => Fuel consumption reduction
  • •Raw material saving
  • •Material recyclability
  • •Clean & eco-friendly process => FSW

THE PROJECT : EVENTS & NEWS

 

> Installation of FUN HEAD on AVANTIS CNC

> First stirring lines test

 

THE PROJECT : PROJECT PROGRESS

 

 

THE PROJECT : PUBLIC DELIVERABLES

 

  D9-1_Dissemination&Exploitation_Plan.pdf

  D9.2_Communication_and_Dissemination_report.pdf

  Commission_FSW_23_février_Présentation_CB_CW.pdf

CONSORTIUM : PARTNERS

 

 

THE PROJECT : RESULTS

 

ADJUSTABLE PIN

> The new FSW head allows to adjust the length of the pin with only one tool

> The new FSW head allows to vary the length of the pin during the welding process

> Possibility to close the keyhole

Without adjustable pin:

With adjustable pin:

Keyhole at the end of the weld

No more keyhole at the end of the weld

WELDING FORCE CONTROL SYSTEM

> Removal of surface defects with the force control system

UNIVERSAL HEAD FOR STIR WELDING

> Welding of convex geometry R = 200 mm

> Welding of concave geometry R = 200 mm

UNIVERSAL HEAD FOR FRICTION STIR WELDING

> Type of weld geometries on 2024-T3 and 7075-T6 alloys:

Flat Convex R ≥ 200 mm Concave R ≥ 200 mm

> Sheet metal thicknesses: thicknesses of 0.4 mm to 3.0 mm

OPTIMIZATION OF FSW PROCESS PARAMETERS

CARACTERIZATION OF WELDS

> Analysis of butt and lap welds (2024-T3 and 7075-T6)

Tensile tests
Microhardness measurement
Microstructural analyses