EUREKA PROJECT > 2430 EUROSTIR
- SUMMARY
- OUTLINE
- PARTICIPANTS
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UNITED KINGDOM
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UNITED KINGDOM
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UNITED KINGDOM
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UNITED KINGDOM
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UNITED KINGDOM
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UNITED KINGDOM
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GERMANY
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UNITED KINGDOM
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FRANCE
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UNITED KINGDOM
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DENMARK
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UNITED KINGDOM
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UNITED KINGDOM
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UNITED KINGDOM
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POLAND
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UNITED KINGDOM
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DENMARK
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UNITED KINGDOM
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FRANCE
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FRANCE
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SPAIN
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FRANCE
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UNITED KINGDOM
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UNITED KINGDOM
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UNITED KINGDOM
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SWEDEN
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SPAIN
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GERMANY
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UNITED KINGDOM
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UNITED KINGDOM
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UNITED KINGDOM
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EUROPEAN INDUSTRIALISATION OF FRICTION STIR WELDING
FRICTION STIR WELDING (FSW) WILL BE APPLIED TO A RANGE OF MATERIALS/BE RESEARCHED TO ACHIEVE HIGH WELDING SPEEDS IN INCREASED JOINT THICKNESS. PROCESSES WILL BE INDUSTRIALISED FOR REAL COMPONENTS AND APPLIED IN COMMERCIAL PRODUCTION.
Status > FINISHED - 09-May-2007 Technological Area Market Area Start Date > 01-Dec-2000 Duration > 60 Months Participating countries > UNITED KINGDOM, SWEDEN, POLAND, FRANCE, FINLAND, SPAIN, DENMARK, GERMANY | Main contactTWI LTD.
DR. CHRIS PETERS > SECTION MANAGER - MANUFACTURING SUPPORT GROUP Organisation type > Research Institute |
Project Description
This project has the overall objective to accelerate the use of friction stir welding (FSW) in Europe. Although the process is a UK invention and was first used commercially in SWEDEN, the subsequent development has been largely in JAPAN and the USA where huge funds have been invested in the exploitation in the aerospace and railway sectors of industry. The success in JAPAN and the USA makes it clear that FSW will not only be dominant in the automated joining of all relatively soft materials such as aluminium, magnesium and copper, but, due to the very superior joint properties and low cost, will also be applied to other materials and applications where these features are valuable. FSW is too important in automated manufacture for Europe to depend on the slow acquisition of know-how from abroad where the substantial improvements in quality and cost reduction have resulted in a reluctance in technology transfer. FSW has proved to be so industrially valuable that mass application has occurred in JAPAN and the USA before a full understanding or explanation of the technology exists in the public domain. This disadvantages manufacturers in Europe and, in particular, the UK where application is minimal. This will lead to reduced sales of manufactured goods and the project is planned to redress this situation by collaborating to accelerate the attainment of knowledge and proactively disseminating the results to ensure exploitation in Europe. Since capital investment is a necessary consideration in the application, the well proven job shop service route will be used to speed up application. FSW takes the apparent skill, health hazards, and cost out of welding whilst improving quality. Undoubtedly others will copy what is achieved in the UK and elsewhere in Europe, but the project provides lead time because the subtlety of tool design and application is not obvious. Active dissemination can use this lead time to increase product sales, thereby increasing home manufacture and maintaining employment. Keywords: friction, robotics, welding.
Technological Development Envisaged
The R & D Phase of the project will take 2 to 2 and a half years, during which the following tasks will be addressed: (1) Tool development (2) Workpiece materials range (3) FSW productivity (4) FSW flexibility (5) Mechanical properties (6) Dissemination. Matrix management of Tasks and Applications will be conducted by European leaders in their respective fields. The Task objectives are to demonstrate the weldability by feasibility studies with both robots and gantries, and to develop methods and procedures for weld assessment and quality assurance for: (a) High-speed (>2m/min) welding of sheet aluminium alloys without loss in quality (b) Welding aluminium alloys with >20mm thickness (c) FSW of dissimilar materials, i.e. cast-wrought, Mg-Al and Al-steel (d) Robotic, all positional and bobbin tool FSW (e) Improving mechanical properties, i.e. raising strength of the weld and HAZ (f) Developing FSW techniques for Ti, Ni, stainless and ferritic steels (g) Industrialising (a)-(f) above for real components and application in commercial production (h) Achieving a 50% participant SME/OEM implementation within 5 years. Deliverables will be proven welding procedures for test pieces and prototypes in comprehensive detail. Equally important will be the detailed comparison between types of equipment, which will enable potential users to make informed investment choices. The role of the job shops in providing a service to potential users is past proven to be catalytic to investment. A vital project achievement will be the establishment of at least 25 user organisations across Europe within 5 years.
Main contactTRITON TOOLING MR. DENIS ALLEN > http://www.tritontooling.co.uk Organisation type > SME |
Contribution to project
Provide friction stir welding tools according to collaborators' designs.
Expertise
A full service contract manufacturer, TRITON TOOLING specialises in tool making (consultancy, design, manufacture and assembly). TRITON TOOLING is experienced in machining and grinding hard metals and has computerised design facilities for creating advanced tool designs. The company also provides consultancy regarding material selection for wear resistant tools.
Main contactAIRBUS UK LTD.
MR. HUW DAVIES > R & T Organisation type > Large company |
Contribution to project
Manufacture demonstrator components for better, more comfortable and more economical aircraft by applying the innovative joining process. * demonstrate FSW of aluminium-lithium alloys * produce prototype components for in-service trials * To develop quality control methods that satisfy authorities and supervising bodies regarding continued passenger safety.
Expertise
Throughout the history of AIRBUS INDUSTRIE, the defining factor of success has been innovation for passengers and greater value to the operator. New ideas, new materials, and new techniques that allow to satisfy passengers and airlines have enabled them to compete with other manufacturers' products and to increase their market share continuously. The new materials used in AIRBUS INDUSTRIE aircraft ensure longer structural life. AIRBUS INDUSTRIE has long pioneered new materials to reduce weight and improve performance. The A3XX will be the most advanced yet in terms of materials used. It will have new glass fibre/metal laminated composites, aluminium-lithium alloys and carbon fibre reinforced plastics for greater weight reductions.
Main contactCATERPILLAR FRANCE S.A.
CENTER FOR MANUFACTURING EXCELLENCE EUROPE
MR. JEAN-JACQUES JANOSCH > CENTER MANAGER Organisation type > Large company |
Contribution to project
Assess the suitability of friction stir welding for CATERPILLAR's products.
Expertise
The company is the world's leading manufacturer of construction and mining equipment, diesel and natural gas engines and industrial gas turbines. CATERPILLAR is a technology leader in construction, transportation, mining, forestry, energy, logistics, electronics, financing and electric power generation.
Main contactFELBINDER UK LTD MR. WILHELM BEYLAND > TECHNICAL DIRECTOR Organisation type > SME |
Contribution to project
Feasibility study on friction stir welded prototype tanks for silo semi trailers.
Expertise
Manufacturer of specialist silo trailers and containers. Innovative design construction principles and the most modern production techniques are used to optimise the load capacity and the centre of gravity of the vehicles.
Main contactHAWTAL WHITING ENGINEERING LTD.
MR. R. G. MURTY > OPERATIONS DIRECTOR http://www.hawtalwhiting.com/world/europe/eng.html Organisation type > Large company |
Contribution to project
Develop new FSW joint designs that minimise time/ cost of manufacturing automotive components, chassis and body-in- white structures. * support fast-to-market design, engineering and production solutions based on FSW that meet the needs of the automotive industry * increase the industry awareness about FSW by producing demonstrator samples and prototype components.
Expertise
In 1970, four engineers left FORD MOTOR COMPANY to found HAWTAL WHITING. By combining their names 'Haw' from R. Hawker, 'tal' from K. Talbot, 'Whit' from J. Whitecross, and 'ing' from F. Lording, a premier name in global engineering services was born. Today, the Group with some 1,000 personnel is listed on the London Stock Exchange, generating an annual turnover of $70 million. HAWTAL WHITING is a full-service provider to automotive Original Equipment Manufacturers (OEM's) and their tiered suppliers. Their European operations employ 600 experienced and highly specialised technical personnel and occupies some 262,000 sq. ft. (24,000m2) of styling and modelling studios, engineering facilities, workshops, laboratories, and manufacturing space. In ENGLAND, a complete turnkey capability exists to develop and support vehicle and product programmes, while in GERMANY, local engineering facilities provide direct support to industry.
Main contactBLACKS EQUIPMENT LTD.
MR. ROGER A. BLACK > CHAIRMAN AND MANAGING DIRECTOR http://www.tapir.co.uk/blacksequipment Organisation type > SME |
Contribution to project
Establish job shop services for FSW, develop cost data for job shop contract friction welding services, promote the FSW process to potential buyers and establish their know-how on FSW in laboratory experiments.
Expertise
The company was formed over 50 years ago to design and manufacture deep mine hoist safety equipment, a market in which they are still active. In the mid 1960's they diversified into friction welding being the first Western European company to offer rotary friction welding machines commercially. Over the ensuing years a sub-contract friction welding service was established gradually building up eight machines. In 1987 the company led a design and manufacturing project to supply linear friction welding machines to TWI, ROLLS-ROYCE PLC Aerospace Group and later to DEUTSCHE AEROSPACE (MTU). Now the company is designing and manufacturing a prototype linear friction welding machine employing a hydraulic linear actuator to provide the oscillating drive.
Main contactAalto University School of Science and Technology PROF. HANNU HANNINEN > HEAD OF THE LABORATORY OF ENGINEERING MATERIALS Organisation type > University |
Contribution to project
To determine residual stress state of FSW-welded aluminium alloys using portable X-ray diffraction and hole drilling measurement systems.
Expertise
We have a new massive university in Finland from 1 January 2010. It is combined of three already excisting units, please read below: Aalto University A science community spanning technology, trade and art Helsinki University of Technology, Helsinki School of Economics and University of Art and Design will form a new university - Aalto University. It starts operating in January 2010 opening up a world of possibilities for multidisciplinary education and research. The goal for the new university is to be one of the leading institutions in the world in terms of research and education in its own specialised disciplines by 2020 - Please read more at the Aalto University web site (The oldest and largest university of technology in FINLAND, HELSINKI UNIVERSITY OF TECHNOLOGY dates back to the nineteenth century. In 1849 the Helsinki Technical School was founded, marking the beginning of organised technical education in FINLAND. In 1872 the school became the Helsinki Polytechnic School and in 1879 the Helsinki Polytechnic Institute.)
Main contactFWS ENGINEERING LTD.
Organisation type > SME |
Contribution to project
Provide consultancy to first time users of FSW Evaluate the market pull regarding FSW equipment.
Expertise
Friction welding equipment manufacturer, experienced in designing and manufacturing purpose-built machines, but also provide services when existing equipment has to be modernised. They offer a specialised package on installing state-of-the-art Health and Safety devices to older machines, such as emergency stop systems, guards and brakes.
Main contactKLAUS RAISER GMBH DR. ELMAR RAISER > Organisation type > SME |
Contribution to project
Review existing tool designs. Conduct experiments in more than 20mm thick aluminium plates. Establish subcontract services for FSW. Gain expertise in the quality management of commercial FSW production.
Expertise
The Technology and Components company RAISER GMBH was founded in 1969. The company expanded very quickly, and in 1972 Klaus Raiser had his initial introduction to a forge welding process, i.e. rotary friction welding. In 1974 the company was transferred to Eberdingen and, when moving into the modern factory, the first rotary friction welding machine was purchased. The continuing professional development of the company led to an expansion of the production area and manufacturing spectrum. RAISER GMBH is now, for example, one of the leading manufacturers of linear friction welding equipment in Europe.
Contribution to project
Commission weld trials/evaluations, assess market demand for production services/FSW machines, promote concepts for flexible manufacturing/assembly of turn key operations and provide job shop services.
Expertise
Family firm established over 30 years ago. It is dedicated to providing joining and assembly solutions to manufacturing industries. The company's success has been founded upon delivering to the customer cost effective, conceptually sound and innovative engineering solutions. The prime business is the design and manufacture for the joining and assembly of manufactured components employing amongst others rotary friction and resistance welding technology.
Main contactCONSTRUCCIONES Y AUXILIAR DE FERROCARRILES S.A.
MR. JOSE ANTONIO ARANBURU > JEFE DE DEPARTAMENTO DE ESTRUCTURAS DE VEHICULOS Organisation type > Large company |
Contribution to project
The main contributions of CAF in EUROSTIR are: - To analyse the product family for joints which could potentially be made by FSW (ceilings and walls). - To carry out FSW tests in the different types of profiles that could be part of such joints. - To verify the quality of the FSW joints. - To apply the acquired knowledge to the design of the construction of train components.
Expertise
The company is one of the international market leaders in the design, manufacture, maintenance and supply of equipment and components for railroad systems. Since its inception, CAF stands out for its versatility and readiness to adapt to customer needs through its: - Product range: From complete transportation systems (urban and suburban, Long Distance Lines) and turnkey services. - Quality: CAF's worldwide experience in compliance with international standards has resulted in a 'total quality' approach to every project. - Research and development: A global conception of the equipment and components for each and every one of the production process stages. CAF has developed important technological advances, such as the SIBI tilting system and the BRAVA gauge change system solutions, to the custom-made parts and components supply and assembly. The technological advances developed by CAF are being successfully used in railroad systems all around the world, providing safety, comfort and satisfaction to millions of users. This is how CAF differs: it fulfils objectives by always adapting to customer's needs and providing the highest level of after-sales service in every project and throughout the life of the products.
Main contactALSTOM TRANSPORT S.A.
MR. JEAN-MICHEL GUILLEMOT > INDUSTRIALISATION MANAGER http://www.transport.alstom.com Organisation type > Large company |
Contribution to project
* To define FSW procedure for the welding of 6000 aluminium alloy, very long extrusions. * To conduct feasibility studies on prototypes.
Expertise
As a leading solutions-provider to the rail industry, ALSTOM TRANSPORT offers its customers a complete range of products and services from integrated transport systems, rolling stock of all types through signalling and train- control systems to complete customer service packages.
Main contactCIRCLE TECHNICAL SERVICES LTD.
MR. GORDON R. BLAKEMORE > PRODUCT MANAGER Organisation type > SME |
Contribution to project
Establish a job shop service for fabrication and repair, demonstrate that FSW can be used under water/subsea down down to 1,000 metres and develop FSW procedures in potentially explosive environments. Friction stir weld demonstrator parts of dissimilar materials for the offshore industry.
Expertise
CIRCLE HIRE AND TECHNICAL SERVICES LTD. were established in 1990 to provide high-pressure water pumps and diver held dredge units for hire to subsea contractors operating in the North Sea. To meet specific customer needs and changing market trends, integrated engineered solutions were developed and offered to the subsea contractors. These include equipment and trained operators working on a contract basis. The change in direction was marked by a recent change of the company name. Following a management buyout in 1999, the company is well placed to service the worldwide underwater and offshore maintenance industry.
Main contactFORCE TECHNOLOGY
DR. JENS ROESTED-CHRISTIAN > VICE PRESIDENT Organisation type > Research Institute |
Contribution to project
Improve the mechanical properties of friction stir welds, particularly for heat-treated aluminium alloys, generate procedures for non-destructive testing and quality assurance of friction stir welds. * improve the weld strength by reducing the heat input, e.g. by improved tool designs, increased welding speeds or artificial cooling * industrialise cooling methods * generate and provide data for fracture toughness of friction stir welds.
Expertise
Independent non-profit institution, which is approved by the DANISH MINISTRY OF BUSINESS AND INDUSTRY as a technological service institute and is affiliated to the DANISH ACADEMY OF TECHNICAL SCIENCES. The FORCE INSTITUTE has 700 employees who are specialised in production technology, materials, inspection, testing, energy, metrology, mechatronics and sensor technology. Each year, more than 6500 Danish companies hire the FORCE INSTITUTE to perform services.
Main contactDLR - INSTITUTE OF MATERIALS RESEARCH
DEUTSCHES ZENTRUM FUER LUFT- UND RAUMFAHRT E.V. DR. HUBERT DOEKER > Organisation type > Research Institute |
Contribution to project
Develop a closed-loop force control system for FSW, evaluate the mechanical properties of friction stir welds in recently developed aluminium alloys and investigate their microstructural characteristics. * generate data for a better understanding of strength and toughness properties, fatigue performance and corrosion behaviour of friction stir welds * optimise the FSW process for industrialisation in the manufacture of civil aircraft. * enhance the competitiveness of national and European aviation industry by dissemination of the research results.
Expertise
DLR is GERMANY's national aerospace centre as well as the national space agency. It serves scientific, economic, and social demands. It has the objective to make a valuable contribution to aeronautics and space flight and to securing and shaping our future. The Institute of Materials Research of DLR develops and characterises structural and functional materials designed for aeronautics, space flight, and energy technology applications. The research activities are linked closely to mid or long-term objectives of industry and national requirements. In the case of questions related to fundamental research, co-operations can be formed with universities and national laboratories. At the Institute of Materials Research, the fatigue behaviour and residual strength of friction stir welded aluminium alloy joints is being assessed under service loading conditions and compared to conventional riveted joints. Environmental effects on crack propagation are also investigated.
Main contactTWI LTD.
DR. CHRIS PETERS > SECTION MANAGER - MANUFACTURING SUPPORT GROUP Organisation type > Research Institute |
Contribution to project
Project Management: develop innovative FSW tool designs and and new welding procedures to increase industrialisation of FSW, train/coach potential FSW operators and technical staff. Contribution: Disseminate at conferences and exhibitions how environmentally-friendly and economic the FSW process is.
Expertise
Provides services to industry and individuals worldwide. It encompasses a professional engineering institution, an international training and certification activity and a large consultancy R & D establishment dedicated to transferring technology to industry. It is one of Europe's largest independent contract research and technology organisations. Over 400 staff, with a unique blend of technical backgrounds, international experience and language skills, work regularly with some 2500 companies in over 50 countries to apply joining technology effectively. TWI invented and patented the friction stir welding process in 1991.
Main contactBRABY LTD.
MR. J. P. LEE > MANAGING DIRECTOR Organisation type > SME |
Contribution to project
Develop joint designs and welding procedures suitable for FSW of silo components thus reducing the cost, develop concepts for erecting silos on the assembly site by using transportable FSW equipment. * demonstrate the time saving effects between receipt of purchase order and delivery by using a modular silo concept to be assembled by FSW * eliminate welding fumes, dust, light emissions and spatter in the welding shop.
Expertise
The UK's leading manufacturer of aluminium and stainless steel silos. They offer silo packages designed to meet their customers' needs. BRABY are experts in handling huge silos and are able to supply silos manufactured, delivered and erected from their purpose-built plant in Bristol to all places of the world.
Main contactRAILWAY SAFETY MR. AQEEL JANJUA > http://www.railwaysafety.org.uk Organisation type > Large company |
Contribution to project
Chair a workshop in Spring 2002 where the rail industry will agree an R&D programme on FSW. Assess potential applications of FSW for laying and repair of rail related infrastructure. Develop criteria for the fitness for purpose assessment of friction stir welded structures. Develop guidelines and standards for state of the art production methods incorporating FSW. Produce demonstrator parts and compare these components with conventionally made components.
Expertise
The company is a not-for-profit, wholly owned subsidiary of RAILTRACK GROUP PLC. RAILWAY SAFETY is limited by guarantee and separate from its operational sister company, RAILTRACK PLC. RAILWAY SAFETY operates as a centre of excellence for all matters relating to railway safety. As well as taking over many of the functions of the former Safety and Standards Directorate within RAILTRACK PLC, RAILWAY SAFETY has an expanded role to help focus the industry on improved safety management. Its vision is to build a justified public confidence that the U.K. railways are safe and developing safely.
Main contactINSTYTUT SPAWALNICTWA
DR. ADAM PIETRAS > Organisation type > Research Institute |
Contribution to project
Conduct destructive/non-destructive testing of FSW samples, obtain approval for FSW procedures by classification societies and technical inspection offices. * provide consulting in the field of design, selection of technological parameters, economics, weld quality and emission of air pollutants * contribute to the development of quality systems for FSW production (according to ISO 9000 and EN 729).
Expertise
The Polish Welding Institute and Member of the INTERNATIONAL INSTITUTE OF WELDING. Their test procedures are accredited by the POLISH CENTRE FOR TESTING AND CERTIFICATION. They are experienced in testing of welding equipment, and the results can be used for safety sign certification, to obtain permission for production or import, or to obtain the certificate of conformity with standards.
Main contactINSTITUT DE SOUDURE (Paris Nord2) DR. CHRISTIAN BOUCHER > COORDINATEUR DE RECHERCHE Organisation type > Research Institute |
Contribution to project
Disseminate FSW technology to the French-speaking community, provide consultancy regarding advantages and limitations of FSW, conduct laboratory experiments on welding parameters/tool designs, evaluate FSW weld quality.
Expertise
This is the French Welding Institute. They provide a wide range of services on welding technologies. They can provide consultancy on welding procedures and have a laboratory for accredited testing services.
Main contactANGEL TRAINS LIMITED MAR. BARRIE COTTAM > Organisation type > Large company |
Contribution to project
Foster the adoption of FSW within the railway industry, where there are clear cost, reliability or safety benefits. Assess the project results and disseminate the results within the rail industry. Compare joint performance of friction stir welded and fusion welded aluminium alloys. Exploit the advantages of friction stir welded rail vehicles, e.g. the reduced manufacturing costs and improved crash worthiness. Provide FSW related consultancy and advice to tram owners and operators on a broad spectrum of technical and commercial issues, including procurement and project management.
Expertise
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Main contactVTT/INDUSTRIAL SYSTEMS
TECHNICAL RESEARCH CENTRE OF FINLAND MR. MIKA SIREN > Organisation type > Governm./Nat. Admin. |
Contribution to project
Conduct destructive and non-destructive testing on FSW joints. Provide expertise and equipment for realisation of a real-time NDT system to HUT's FSW machine. Model and simulate the residual stress state of FSW structures as well as their behaviour during and after welding.
Expertise
The Research Centre is today the largest research organisation in Northern Europe. VTT is an impartial, multi-disciplinary, non-profit organisation carrying out research and development work, technology transfer and testing. Welding and joining research has a long and prosperous history at VTT. Apart from steels, aluminium has been one of the topics of welding research activities since the late 1970's. The main emphasis has focused on manufacture and repair techniques for welded aluminium structures in transportation industries, mainly marine and rail applications.
Main contactDANSTIR APS
MR. TORBEN LORENTZEN > Organisation type > Large company |
Contribution to project
Generate a market for prefabricated aluminium parts in several industrial sectors demonstrate the advantages and limitations of friction stir welded components appraise and benchmark commercially available FSW machines. Provide job shop services for FSW.
Expertise
New company, which was set up in DENMARK to provide subcontract FSW services mainly to the Danish market. They conduct feasibility studies on FSW and weld prototypes, develop welding procedures and provide advice on advantages and limitations of the FSW process.
Main contactMAGICSCOPE
MR. G.J. WADLEY > MANAGING DIRECTOR Organisation type > SME |
Contribution to project
Evaluate FSW of austenitic stainless steel for the production of medical equipment and electron microscopes and produce prototype parts for the above.
Expertise
Manufacturer of very specialised chambers for electron microscopes together with glove boxes and innovative chambers for the medical and pharmaceutical industries, where high quality is required. They are known for providing highly polished surfaces with high precision. Their product range includes also air filtration units for laboratories and clean rooms, funnels for filling machines and vessels for the chemical industry.
Main contactSNECMA MOTEURS
MR. JEAN-PIERRE FERTE > METALLURGICAL JOINING, SECTION MANAGER Organisation type > Large company |
Contribution to project
* To conduct laboratory experiments on welding parameters and tool design for welding of titanium and aluminium alloys used in aircraft engines. * to conduct feasibility studies on prototypes.
Expertise
The 3 core businesses of SNECMA Group are the propulsion, the equipment and the services. SNECMA MOTEURS is involved in both space and aeronautic propulsion. With 13,840 employees, SNECMA MOTEURS is one of the world's largest aircraft engine manufacturers with over 50 years experience. SNECMA MOTEURS designs, develops, manufactures, and sells engines which power DASSAULT aircraft, medium and long range AIRBUS and BOEING aircraft flying under the colours of more than 250 airlines. At the end of 1999 more than 9,500 CFM56 engines had been delivered. SNECMA MOTEURS represents about 22% of the market share for the engines dedicated to commercial aircraft over 100 seats. Through its rocket engine division (former SEP), SNECMA MOTEURS is the world leader in the field of rocket propulsion. At the end of 1998, 1,125 rocket engines had been ordered. In technology research SNECMA MOTEURS collaborates with more than 50 European laboratories, universities and research centres. These research programmes cover a broad spectrum of fields, so that SNECMA MOTEURS has gained a reputation of excellence in the most important engine technologies. The turnover of the group is 28,5 Billion FRF (4,3 Billion Euro) with 21,7 Billion FRF (3,3 Billion Euro) for SNECMA MOTEURS itself.
Contribution to project
Improve the productivity of FSW by increasing welding speeds, minimise set-up and knock-down times, assist flexible manufacturing by evaluating robotic FSW systems. * reduce the generation of flash beside friction stir welds * provide expertise on closed-loop force control and three- dimensional joint lines.
Expertise
With a staff of approximately 800 employees at its sites near Hamburg and Berlin, GKSS is one of the 16 national facilities belonging to the HERMAN VAN HELMHOLZ ASSOCIATION OF GERMAN RESEARCH CENTRES. GKSS conducts scientific and technological R & D and has inter- disciplinary and international co-operations with other scientific institutions. One of their main activities is associated with materials research in the field of metallic materials and polymers.
Main contactPECHINEY RHENALU MR. HENRI GERARD > WELDING DEVELOPMENT MANAGER Organisation type > Large company |
Contribution to project
The company's contribution to the EUROSTIR project deals with the industrialisation of FSW. Technically, the feasibility of welding very large thick plates has not been fully addressed. The purpose of PECHINEY is to develop, with other institutions, the skills and specifications needed to weld typical wing sub-components in very high strength alloys like AA7449. Large test testing of these large weldments will be performed: R-curve, fatigue crack growth under variable amplitude loading, in-site corrosion. In addition to this contribution, PECHINEY will contribute with newly developed alloys to the partners in the programme in order to keep the project up to date with the latest developments in aircraft programmes in terms of aluminium alloys.
Expertise
The world's fourth largest producer and converter of aluminium, PECHINEY operates in all facets of aluminium production (bauxite, alumina, primary aluminium). PECHINEY's electrolysis technique is recognised as one of the most efficient in the world. PECHINEY is also one of Europe's leading aluminium converters for transport markets, industrial applications, construction, household appliances and packaging.
Main contactIRIZAR. S. COOP. MR. PELLO URTEAGA > PRODUCT INNOVATION COORDINATOR Organisation type > Large company |
Contribution to project
- To analyse the product family for applications of FSW in the construction of coach components. - To re-design the product to adapt it to new joint processes. - To evaluate the technical and economical viability of the components coach made with FSW. - To construct a coach component made by FSW.
Expertise
A business project based on people, IRIZAR is built on a system of self-management and participation, with the goal of achieving Business Excellence through the continuous satisfaction of its customers, people, external collaborators and society at large, thus generating social wealth and employment. IRIZAR is a luxury coach maker. It is the market leader in SPAIN, Europe's second biggest producer by volume, and is commercially active in 44 countries. The number of people involved in the Ormaiztegi operation in Gipuzkoa, a province within SPAIN's Basque Country, currently stands at 634. IRIZAR was founded in 1889, and is one of the 100 autonomous co-operatives that make up the MONDRAGON CORPORACION COOPERATIVA (MCC) Group. The IRIZAR Group, founded in 1998 as a consequence of the IRIZAR partnership strategy, includes IRIZAR TIANJIN (CHINA, 1995), IRIZAR MAGHREB (MOROCCO, 1997), IRIZAR BRAZIL (1998), IRIZAR MEXICO (1999) and INTERNATIONAL HISPACOLD (SPAIN, 1997). The progress of IRIZAR towards Business Excellence has been recognised through various awards and accolades.
Main contactEADS CCR
MR. JACQUES BOURIQUET > HEAD OF METALLIC MATERIALS Organisation type > Large company |
Contribution to project
On Steering Group/Technical Committee. Will conduct lab. experiments on welding parameters/tool design to weld HS aluminium alloys. Will manufacture FSW demonstrator components for better, safer and more economic aircraft.
Expertise
One of the 3 partners of the multinational EUROPEAN AERONAUTIC DEFENCE AND SPACE CO. (EADS N.V.). The latter is the world's first transnational aerospace company. The 3 partner companies have been co-operating successfully for over 40 years on numerous projects and joint ventures like AIRBUS, EUROCOPTER, EUROFIGHTER and ARIANESPACE and achieve more than 70% of their respective revenues within common structures. EADS N. V. comprises the activities of the founding partners AEROSPATIALE MATRA S.A. (FRANCE), CONSTRUCCIONES AERONAUTICAS S.A. (SPAIN) and DAIMLERCHRYSLER AEROSPACE AG (GERMANY). The new company celebrated Day One together with its listing at the Madrid, Munich and Paris stock exchanges on July 10, 2000. In terms of market share, EADS N.V. is one of the top two manufacturers of commercial aircraft, civil helicopters, commercial space launchers and missiles. EADS N.V. is also a leading supplier of satellites and electronics.
Main contactSECO ALUMINIUM LTD.
MR. DAVID E. BEALE > MANAGING DIRECTOR http://www.secoaluminium.co.uk Organisation type > SME |
Contribution to project
Offer constructive and innovative technical support on joining extrusions by FSW, improve design, to minimise fabrication cost and time and to reduce the weight of prefabricated panels. * develop FSW applications in conjunction with major Civil Engineering organisations * provide information on environmental management and recycling when using friction stir welded aluminium components.
Expertise
Has been at the forefront of the aluminium extrusions industry since it entered the field in 1965. During this time the company has built up and maintained a reputation for providing high quality extruded aluminium sections to tight delivery schedules at competitive prices. SECO has a very broad and diverse range of existing customers in the UK and in many other places including countries on the European, American and African continents.
Contribution to project
Develop concepts for FSW contract-manufacturing services for the food and beverage industries, offer a range of friction stir welded products for the process blocks of breweries, such as tankage, pipework and filtration. * evaluate how automated FSW systems could be built while advocating the adoption of International Industry Standards.
Expertise
A division of BRIGGS OF BURTON. BRIGGS OF BURTON offer total capability, right across the board, from brewhouse to warehouse. Their core divisions offer everything from mash conversion, lautering, wort boiling, separation, fermentation, maturation and conditioning, through automation and control systems, to complete project management, consultancy, design and feasibility studies. In the International brewing industry of today, BRIGGS OF BURTON PLC enjoy an outstanding reputation. It gives testimony to a group of companies whose global capability has sprung from engineering skills first developed at the beginning of the 18th century.
Main contactTHOMPSON FRICTION WELDING
Organisation type > SME |
Contribution to project
Provide a computerised system for continuously monitoring significant FSW parameters throughout the weld cycle to ensure that top quality components are produced at all times. * provide advice on interfaces between the FSW machine and robots which place the welded components onto the exit conveyor system * offer a job shop service.
Expertise
Established in 1962, the company designs and manufactures rotary friction welding machines with a range from 8 to 250t forge capacity for customers in the UK and overseas. Around 95% of their machines are exported to customers around the world to countries including SWEDEN, INDIA, and the USA. They also provide a sub-contract friction welding service using their own machines. Some THOMPSON machines are fitted with automated loading and unloading systems, which handle the un-welded and welded components.
Main contactESAB AUTOMATION AB
MR. LARS-GOERAN ERIKSSON > DIVISIONAL MANAGER Organisation type > Large company |
Contribution to project
Improve the flexibility of FSW systems, provide kinematics for two-dimensional or three-dimensional joint lines, supply a computer-based control system/software, develop clamping methods/fixtures and innovative FSW tool concepts.
Expertise
Provides consumables and equipment for virtually all welding and cutting processes and applications. Almost 100 years of continuous research, development and manufacture have made ESAB the world leader in welding and cutting, and also an international supplier of products, know-how and services. ESAB offers a variety of purpose built FSW machines developed from a standardised base unit and with working envelopes ranging from 0.5 x 1.5 to 10 x 20m. They also supply models of the gantry type.
Main contactFundacion FATRONIK MS. MARIA ASUNCION RIVERO > R & D ENGINEER Organisation type > Research Institute |
Contribution to project
The main contributions of FATRONIK to this project are: - To analyse industrial partners' (IRIZAR, CAF) product family for suitable applications of FSW. - To analyse using parallel kinematics actuation system for friction stir welding. - Monitoring and online compensation (i.e. closed loop control) of friction stir welding parameters. - Design, development and set up of specific FSW machinery solutions for industrial partners.
Expertise
The Institute was born in 1986 in order to satisfy the technology-related needs of a Group of machine tool manufacturers. From 1999 onwards, FATRONIK consolidated as a Technological Centre specialising in mechatronic technologies and targeted the market of Equipment Goods, including renewable energies (mainly wind energy) and aeronautics in the fields of component tooling and the development of solutions for the automation of structure assembly. During the last 11 years, FATRONIK has improved existing products and devised new solutions, as well as created new designs with innovative final results that comply with market demand. It consists of 50 employees and more than 30 engineers. Nowadays FATRONIK is one of the most relevant technological referents in the Machine Tool sector nationwide, and its presence abroad is growing progressively. FATRONIK has an active presence in European research activities, and is currently leading three GROWTH projects: - MACH 21: Multipurpose and cross-sectorial modernisation of manufacturing processes through parallel kinematics. - AHEAD: New way of manufacturing large non-rigid structures through innovative production systems. - SMART: Total service for the machine tool end-user.
Main contactAIRBUS DEUTSCHLAND GMBH MRS. DANIELLA LOHWASSER > Organisation type > Large company |
Contribution to project
The main contribution will be regarding weld properties and productivity. AIRBUS will friction stir weld prototype components using TWI's new FSW machine. In order to achieve the cost and weight targets, a large number of subcomponent tests will be performed for supporting the design and evaluation of the metallic fuselage barrel test. The final validation of the new techniques will be provided by the metallic fuselage barrel, which represents a rear fuselage section of a wide-body transport aircraft under loading conditions.
Expertise
R&D capabilities of AIRBUS cover all aspects of aircraft design and optimisation (aerodynamics, aeroelastics, structures, weights, performances, operating costs, environmental aspects, etc.), airframe and systems development and engine integration.
Main contactSMART TECHNOLOGY GROUP - CRAWFORD SWIFT MR. JONATHAN MARTIN > http://www.crawfordswift.co.uk Organisation type > SME |
Contribution to project
Provide confidential advice and consultancy on machine tools, control systems and fixture design. Conduct industrialisation programmes with potential customers. Design and manufacture equipment for potential customers. Disseminate benefits of the FSW process.
Expertise
In 2001, SMART TECHNOLOGY GROUP LIMITED was formed with the aim of providing resources and support to achieve a dynamic forward thinking group based around a core traditional machine tool business whilst introducing new high tech solutions. The group's philosophy is to build a world-class solutions provider.
Main contactH.C. STARCK LIMITED EUR. ING. CHARLES E.D. ROWE > TECHNICAL MANAGER Organisation type > SME |
Contribution to project
Supply refractory metals for FSW tools. Provide design support on a confidential basis. Assess the suitability of commercially available alloys for FSW of materials with high melting points.
Expertise
The company offers a unique service in the field of refractory metal processing. Its experts provide answers and solutions to challenges and problems in all areas ranging from construction to alloying. In co-operation with its customers, it has used many years of experience to solve all construction and material problems emerging from the development and improvement of refractory metals.
Main contactCORUS
Organisation type > Large company |
Contribution to project
Transfer know-how and experience to collaborating companies, disseminate the advantages of the FSW process at conferences and exhibitions and by publishing technical papers. * attract funding for further industrial R&D projects on FSW * prepare technical reports and manuals on FSW * pursue FSW of steels, aluminium alloys and dissimilar combinations.
Expertise
The CORUS GROUP, which came into existence in 1999, is the result of the merger between BRITISH STEEL and KONINKLIJKE HOOGOVENS. CORUS is Europe's largest steel producer (third largest in the world) and a leading aluminium producer. CORUS' main markets are in the construction, automotive, packaging, aerospace, shipbuilding, rail transport, energy and engineering industries. CORUS has a growing network of downstream operations, with ongoing investments being made in various regions. With a focus on providing value-added products and services to the customer, coupled with local market knowledge, these ventures consist primarily of service centres and steel profiling operations for the construction sector.