Germany – Industrial machinery – hybride Rührreibschweißanlage (FSW Anlage)

Preamble

The Helmholtz-Zentrum hereon GmbH (Hereon) is a non-profit research institution and one of the 18 member institutions of the Hermann von Helmholtz-Gemeinschaft Deutscher Forschungszentren e. V. The costs of Hereon are funded 90% by the Federal Government (BMBF - Federal Ministry of Education and Research) and 10% by the four consortium states (Schleswig-Holstein, Hamburg, Niedersachsen and Brandenburg). The statutory task of the society is to conduct research and development in a multidisciplinary network, particularly in the fields of materials research, coastal, climate and environmental research, as well as regenerative medicine.

Technical Description: Preliminary draft of the specification for the procurement of a hybrid friction stir welding system (FSW system)

The specification for a hybrid FSW system (friction stir welding) includes the technical specification for joining materials in the solid phase and typically includes the core areas of mechanics/force absorption, process control and quality assurance. Detailed process monitoring enables the long-term collection of high-quality datasets for the development of digital twins and live feedback in process control. Designed for high axial and feed forces with minimal machine deflection.

Technical Main Features

- Machine type: Rigid C-frame design (combinable with milling machining) in double-spindle configuration. Frame designed for 200kN axial force

- Length of the welding table (X-axis) main welding direction (desired 5.5 m) and option for extension

- Table width (Y-axis) 2m

- Table height max. 1.10m

- Travel range upper spindle (Z-axis): min. 600 mm (working height min.: 600mm relative to tool tip)

- Table with recess for lower spindle module; with interchangeable plate to adjust the gap for the lower tool accordingly

- Welding speed: up to max. 6 m/min = 100 mm/s

- Option for lead roller with force control

- Double spindle concept: Torque-strong FSW spindles for rotating tools with variable speed and precise position control. The upper spindle should be interchangeable with training of Hereon personnel by the manufacturer to, for example, switch to a spindle for higher forces and higher torques at lower speeds (e.g. 200kN, 2000Nm, 3000rpm) in the future

- Coordinate system upper spindle system (x, y, z) and lower spindle system (u, v, w); x and u must meet the same performance data to run synchronously

- Runout max. 0.02 mm

- Spindle 1 (upper spindle): This spindle unit is arranged on the vertical axis at the top so that the friction stir welding tool reaches the material to be joined from above

- Required process variants:

- FSW - Friction Stir Welding (friction stir welding)

- SS-FSW - Stationary Shoulder FSW (stationary shoulder friction stir welding)

- Retractable Probe - Retractable welding pin

- BT-FSW - Bobbin tool FSW (double shoulder friction stir welding)

- SSBT-FSW - Stationary Shoulder bobbin tool FSW (stationary double shoulder friction stir welding)

- HBT-FSW- Hybrid Bobbin Tool FSW (hybrid double shoulder friction stir welding) where both shoulders can be operated at independent speeds

- Adititive Friction Stir Deposition (AFSD) (shoulder friction deposition welding) - continuous material feed optional

- Optional: Refill Friction Stir Spot Welding (ReFSSW)

- Requirements (all forces relative to tool tip):

- Axial force Fz: 100 kN

- Force in welding direction Fx or force perpendicular to welding direction Fy: radial 35 kN

- Torque: min. 1000 Nm

- Rotational speed welding pin/ lower shoulder: min. 6000 rpm

- Spindle power: ~70 kW

- Axial force on the welding pin min. +/-35 kN

- Weld penetration depth: 25 mm

- Retraction for retractable welding pin (eng. retractable probe); separate pin axis

- Adjustment angle: +/- 5° manually / automated in x-axis

- Tool cooling (2.5 - 3 kW cooling capacity)

- Shielding gas supply

- AFSD module min. 35kN for 2 consumables, each min. 500mm length; 10 to 15mm diameter

- Spindle 2 (lower spindle):

- Process variants:

- FSW - Friction Stir Welding (friction stir welding)

- SS-FSW - Stationary Shoulder FSW (stationary shoulder friction stir welding)

- Requirements:

- Axial force Fz: min. 100 kN

- Force in welding direction Fx or force perpendicular to welding direction Fy: radial min. 35 kN

- Torque: min 1000 Nm

- Rotational speed welding pin/ lower shoulder: min. 6000 rpm

- Spindle power: ~70 kW

- Axial travel: +/- 15 mm

- Shielding gas supply

- Tool cooling (2.5 - 3 kW cooling capacity)