Welding in Aircraft and Aerospace Conference

Transcription

1 Welding in Aircraft and Aerospace Conference Wichita, Kansas September 16-17, 2008 The aircraft and aerospace industry is making great strides in cost reduction. One aspect of this is utilizing composites in place of aluminum. Another innovation is to build critical parts from the ground up, rather than ordering expensive forgings and castings that have to be machined down to size. Welding is in the very thick of it on both fronts. Improved processes are being developed to weld carbon fiber composite structures. In the world of born to shape parts, innovative welding processes like electron beam, laser, and others are getting the job done efficiently and economically. Founded in 1919 to advance the science, technology and application of welding and allied joining and cutting processes, including brazing, soldering and thermal spraying.

2 At this AWS conference in Wichita, emphasis will be given to friction stir welding, fiber laser welding, and the gas-shielded welding processes. The role of titanium is growing, and the emergence of a number of new aluminum-lithium alloys poses new welding challenges. Ultrasonically assisted thermal stir welding will be on the agenda, as well. Plans for vehicles to carry humans to the moon by 2010 (and later, to Mars) will also be discussed. CONFERENCE PROGRAM TUESDAY, SEPTEMBER 16, 2008 CONTINENTAL BREAKFAST 8:00 a.m. 9:00 a.m. WELCOME 9:00 a.m. 9:15 a.m. Robert R. Irving, Conference Chairman Jeff Ding, Conference Co-Chairman Titanium Friction Stir Welding and Laser Welding Development for Commercial Aircraft 9:15 a.m. 9:55 a.m. Daniel G. Sanders, Senior Technical Fellow, Director of M&P Science, Materials & Process Technology, The Boeing Co. The use of titanium for commercial aircraft built on primarily a composite materials platform has increased dramatically. This is due to the performance advantage over aluminum alloys in regards to galvanic corrosion, coefficient of thermal expansion, strength-to-weight ratio, and elevated temperature applications. However, titanium is expensive to manufacture as a raw material and to process. This paper will focus on recent advances made to develop the titanium friction stir welding and fiber laser manufacturing processes. Potential Uses for Fiber Lasers in Aerospace Application 9:55 a.m. 10:35 a.m. Paul Denney, Laser Researcher, Connecticut Center for Advanced Technology, Inc., Hartford, CT The Connecticut Center for Advanced Technology, (CCAT) is investigating the use of the fiber laser for aerospace applications. This includes welding as well as drilling and cutting. CCAT will report on some of its preliminary results in these areas and what it may mean to the industry. The presentation will also discuss CCAT s effort with Coast Composites to use a 10kW fiber laser for the fabrication of wing molds for large commercial aircraft. MORNING BREAK 10:35 a.m. 10:50 a.m. Friction Stir Weld Assembly of the Eclipse 500 Very Light Jet 10:50 a.m. 11:30 a.m. Brent Christner, Manager, Materials and Process Engineering, Eclipse Aviation, Albuquerque, NM The Eclipse 500 VLJ is now FAA-approved and in full production. Almost all of the mechanical fastening associated with the buildup of conventionally stiffened aircraft skin panels has been replaced by friction stir welding (FSW). This presentation will cover the steps taken to get FSW implemented into production, production start-up obstacles, FSW tooling approaches, and the current status of the FSW process at Eclipse. Data will presented on the cost and cycle time advantages of using the FSW process. Electron Beam System Technology for Welding and Additive Manufacturing 11:30 a.m. 12:10 p.m. Robert C. Salo,Sales Manager, Western Region, Sciaky, Inc., Chicago, IL This presentation will cover a layer additive manufacturing process using CNC-controlled electron beam (EB) systems with wire feed as a manufacturing method. Examples will be reviewed that will include applications and property data. An EB diagnostic tool design will also be described that will improve performance of all EB systems (either welding or additive manufacturing). LUNCH (PROVIDED) 12:15 p.m. 1:15 p.m.

3 High Powered Ultrasonics and Thermal Stir Welding 1:15 p.m. 1:55 p.m. Jeff Ding, Aerospace Welding Engineer, NASA Marshall Space Flight Center, Huntsville, AL Thermal stir welding (TSW) is a new solid-state welding concept that decouples the heating, stirring and forging elements of friction stir welding to allow independent control of each process element. A new TSW system, designed for the joining of inchthick, high melting temperature alloys, such as titanium and steels, has been delivered to Marshall Space Flight Center. TSW weld data will be presented for commercially pure titanium and Haynes 230 alloys. In addition, the TSW system serves as a test bed for high-powered ultrasonics (HPU) technology development. Data will be presented on high-power ultrasonically assisted drilling and welding applications. Advanced Manufacturing and Repair of Nickel and Titanium Alloys 1:55 p.m. 2:35 p.m. Nick Kapustka, Applications Engineer, Arc Welding, Lasers & Automation, Edison Welding Institute, Columbus, OH Due to high material cost, long lead times, and increasing performance requirements for engine and airframe components, advance manufacturing and repair technologies are of increasing interest. Precision GMAW additive manufacturing of titanium structural components and laser/laser-arc-hybrid welding of titanium- and nickel-based alloys will be discussed. Solid-state welding of these alloys, including friction stir and projection welding, will also be presented. Development of Third-Generation of Aluminum Lithium Alloys 2:35 p.m. 3:15 p.m. Michael Niedzinski, Director of Technology and Standardization USA, Alcan Aerospace, Chicago, IL During the past 15 years, aluminum producers put significant R&D effort into development of optimized third-generation Al-Li alloys which are characterized by static properties and fracture properties equal to or better than conventional 2XXX and 7XXX series alloys, while at the same time providing superior corrosion resistance, higher modulus and 5-7% lower density. These products are viewed as one of the viable alternatives to composites. Attributes of these products will be detailed. Additionally, these products have been successfully friction stir welded. Three examples profiling Alloys 2198, 2050 and 2195 will be described during the presentation. WEDNESDAY, SEPTEMBER 17, 2008 CONTINENTAL BREAKFAST 8:00 a.m. 9:00 a.m. Returning to the Moon: Welding and Fabrication of the Ares I Upper Stage Hardware at Marshall Space Flight Center 9:00 a.m. 9:40 a.m. Jeff Ding, Aerospace Welding Engineer, NASA Marshall Space Flight Center, Huntsville, AL The welding and fabrication of the Ares I upper stage cryogenic test articles require numerous friction stir welding (FSW) systems and stacking/assembly tools. Most of the manufacturing tools reside in a single high bay area designed for optimal product flow. The sequence of fabrication operations will be presented, focusing on the FSW tools and applications. Path Independence of Friction Stir Welding 9:40 a.m. 10:20 a.m. Dr. Dwight Burford, Senior Research Scientist, Director, Advanced Joining & Processing, National Institute for Aviation Research, Wichita State University, Wichita, KS It has been demonstrated that a number of different tool designs can be used to produce a sound friction stir welded joint in inch 2024-T351. These results are in reasonable agreement with reported results for 2024-T3 in a range of thicknesses. This is not to suggest that one tool does not provide any particular advantage over another in terms of productivity, fatigue, etc. For design values or a performance specification, it is unnecessary to define exact tool geometries. Tool geometries would be found in the weld process specifications of individual suppliers or producers, but should not be a requirement to meet performance goals. MORNING BREAK 10:20 a.m. 10:35 a.m. Aerospace Gas Tungsten Welding 10:35 a.m. 11:15 a.m. Wyatt Swaim, Chief Executive Officer, WJS Consulting Inc., Springs, KS This topic will cover how aerospace and aircraft welding techniques have affected the racing world. Brief discussions will cover materials such as titanium, 4130 Cr-Mo steel, and certain stainless steels. One of the most surprising revelations involves the NASCAR C.O.T. (car of tomorrow).

4 Developments in Usage of Fiber Lasers for Aerospace Welding Applications 11:15 a.m. 11:55 a.m. Eric Stiles, Applications Manager, IPG Midwest Operations, IPG Photonics, Wixom, MI Advances in industrial fiber laser technology in the last few years has increased interest in the usage of laser welding for aerospace applications. Fiber lasers offer power levels and beam quality not previously available for fiber delivered lasers, making them interesting for a wide variety of applications. This presentation will show examples of the welding capability of the fiber laser for aerospace materials, and discuss existing and potential applications. LUNCH (PROVIDED) 12:00 p.m. 1:00 p.m. Laser Weldbonding of Thin Aluminum Structures 1:00 p.m. 1:40 p.m. George Ritter, Technology Leader, Plastics and Adhesives, Edison Welding Institute, Columbus, OH Riveted thin aluminum structure is the norm for general aviation aircraft, requiring custom labor input with little chance for automation. Robotic laser weldbonding combines adhesive bonding and laser welding for thin aluminum structures. This approach provides fiberoptic access to narrow spaces and combines the shear strength of adhesive bonding with the peel strength of welds. Advantages of weldbonding and representative joint performance data will be presented along with examples of structures produced using this technique. Metal Part Fabrication and Component Repair with Laser Engineered Net Shaping 1:40 p.m. 2:20 p.m. Rich Plourde, Director, Aerospace and Defense Business Development, Optomec, Inc., Albuquerque, NM Laser Engineered Net Shaping (LENS) is an emerging art-to-part additive manufacturing technology which allows metal components to be fabricated directly from CAD data, using metal powder as the material and a high-powered laser as the energy source. LENS also has the capability of adding features to an existing part, casting or forging, using a hybrid manufacturing approach. Optomec Inc. has been at the forefront of additive manufacturing technology development for the past 10 years as a commercialization venture from Sandia National Laboratories, where LENS was invented. This presentation will highlight the historical development of LENS, the current state of the art, and the future possibilities for freeform additive manufacturing technologies. Examples will be used to highlight the use and benefits of LENS for part fabrication, hybrid manufacturing, and component repair applications. Eddy Current Array and Ultrasonic Phased-Array Technologies as Reliable Tools for Inspection of Friction Stir Welds 2:20 p.m. 3:00 p.m. Michael Turner, Advanced Technical Sales, Olympus NDT, Kansas City, MO; and Andre Lamarre, Business Development Director, Aerospace and Defense, Olympus NDT, Quebec City, Quebec Ultrasonic phased-array technology has demonstrated over the years its capabilities to inspect aluminum friction stir welds (FSW) reliably, as many aerospace manufacturers have used it during their manufacturing process. Recent developments in eddy current array technology added new perspectives to the FSW evaluation. It is now possible to characterize the tool penetration and minimize the presence of an oxide layer, so-called kissing bond. This presentation will summarize results of both technologies for the evaluation of FSW. UPCOMING AWS EVENTS The following are among other AWS conferences and events to be held in For detailed descriptions, see Fabtech Int l & AWS Welding Show October 6-8, 2008 Las Vegas New Technologies in Thermal Cutting Conference October 6, 2008 Las Vegas New Nondestructive Testing Technologies Conference October 7, 2008 Las Vegas Friction Stir Welding Conference October 8, 2008 Las Vegas RWMA Resistance Welding School October 2008 Las Vegas Welding of Engineering Plastics & Composites Conference November 11-12, 2008 Orlando For questions or additional copies of this event brochure, call , ext. 455 ( outside of North America)

5 550 N.W. LeJeune Rd. Miami, FL Visit our website AWS Conference on Welding in Aircraft and Aerospace Wichita, Kansas September 16-17, 2008 Conference sessions will cover topics such as: Friction stir and laser welding of titanium, etc. Fiber lasers for welding, cutting, and drilling Electron beam welding Thermal stir welding Additive manufacturing with lasers and electron beams New aluminum-lithium alloys Applications from race cars to jets to spacecraft Aerospace gas tungsten arc welding Robotic laser weldbonding of aluminum Inspection and qualification in friction stir welding NON-PROFIT ORG. U.S. POSTAGE PAID MIAMI, FL PERMIT NO 1005

6 CONFERENCE CODE: COAAC-2 AWS Members: $550 Nonmembers: $680 Each nonmember attendee will receive a two-year complimentary membership in AWS. Your conference registration fee includes all conference sessions, two continental breakfasts, two lunches, and refreshment breaks. The registration fee does not include hotel accommodations. Hotel accommodations are subject to hotel regulations and are the responsibility of the attendee. You will receive a CD containing copies of all presentations, an attendee roster, and a speaker roster for post-event interaction and followup. Each participant will also earn 14 Professional Development Hours (PDHs) for attending the conference. GUARANTEE AWS guarantees that you will leave the conference a satisfied customer. If for any reason you are not satisfied, please send a letter to American Welding Society, Director Conferences and Seminars, 550 NW LeJeune Road, Miami, FL LOCATION AND ACCOMMODATIONS The Broadview 400 W. Douglas Avenue Wichita, Kansas Phone: / Fax: Take advantage of the specially negotiated rate of $109 for single or double occupancy. This special rate is also extended to you three days before the conference and three days after the conference (depending on hotel availability). Be sure to mention the American Welding Society to receive this rate. The deadline for reservations at this special price is August 29, Each reservation must be guaranteed with a major credit card. Any room reservations must be cancelled by five days in advance of the arrival date and must be done directly with the hotel. FOUR EASY WAYS TO REGISTER: 1. Go online: 2. Call: , Ext. 455, between 8 AM and 5 PM EST. Please have your AWS membership number and a purchase order number or credit card ready. 3. FAX form: Fax one copy per registrant. 4. Mail registration form to: American Welding Society P.O. Box , Miami, FL Mail one copy per registrant. Note: Registrant information needed for each registrant Priority Code (from mailing label) AWS Member No. (if any) Name Remit Payment To: American Welding Society P.O. Box Miami, FL Company Title Business Other Address City/State/Zip Daytime Phone Method of Payment: Bill Me (AWS members only) Bill My Company (Must Include Purchase Order No.) P.O. No. Check Money Order VISA MasterCard American Express Diners Club Discover Carte Blanche Card No. Signature Exp. Date Please send me the FREE AWS Product Catalog. I prefer to receive reminders about seminars via Postal mail Code COAAC-2 Conference on Welding in Aircraft and Aerospace REFUND POLICY AWS knows your plans can change and offers a flexible refund policy. If you notify AWS at least two weeks before a scheduled conference that you are unable to attend, you will receive a full refund less a $75 administration/hotel attrition fee. Notification received less than two weeks before the conference will result in a refund less a $175 administration/hotel attrition fee. You may send a substitute with no additional fee. Registration fees will not be refunded for no-shows. Note: AWS reserves the right to cancel any event at its reasonable discretion. In the event of cancellation by AWS, registration fees will be refunded in full. AWS shall have no further liability. Fee AWS USE ONLY 1. Check # 2. Date Rec d 3. Amount 4. Account# ACCOMMODATIONS FOR THE DISABLED Pursuant to the Americans with Disabilities Act (ADA), AWS, and The Broadview strive to ensure accessibility for all guests. If you have special needs, please inform the hotel when you make your reservations, and also contact the AWS Education Services Department at , ext 455.