MTS Presentation

8/8/2019 MTS Presentation

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File: AMPDIR-02-AMP-Rev ADate: June 2002Page: 1

Presented atAEROMAT Conference- 2002 [email protected]

AMPSDSM&T

MultiMulti--Axis Friction Stir WeldingAxis Friction Stir Welding

andandIntelligent Laser ProcessingIntelligent Laser Processing

at theat the

Advanced Materials Processing CenterAdvanced Materials Processing Center

AEROMAT 2002 ConferenceAEROMAT 2002 Conference

June 8June 8 -- 14, 200214, 2002

William ArbegastWilliam ArbegastAdvanced Materials Processing CenterAdvanced Materials Processing Center

South Dakota School of Mines and TechnologySouth Dakota School of Mines and Technology

Rapid City, SDRapid City, SD

Mike SkinnerMike SkinnerAES DivisionAES Division

MTS Systems CorporationMTS Systems Corporation

Eden Prairie, MNEden Prairie, MN


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AMPSDSM&T

The AMP Center is funded under a grant from the ArmyThe AMP Center is funded under a grant from the ArmyResearch Laboratory (ARL), Aberdeen, MDResearch Laboratory (ARL), Aberdeen, MD

Our Industrial partner is the AES Division of MTS Systems, Inc.Our Industrial partner is the AES Division of MTS Systems, Inc.Eden Prarie, MNEden Prarie, MN

Design and fabrication of AMP Center equipmentDesign and fabrication of AMP Center equipment

The SDSM&T AMP Center technologies will focus onThe SDSM&T AMP Center technologies will focus on Friction Stir Processing (FSP)Friction Stir Processing (FSP)

Large, multiLarge, multi--axis FSP equipment capable of joiningaxis FSP equipment capable of joining complexcomplexcurvaturecurvatureseams in thick and thinseams in thick and thin--section materialssection materials

Intelligent Laser Processing (ILP)Intelligent Laser Processing (ILP)

RoboticRobotic directed metal depositiondirected metal depositionandand laser processinglaser processing equipmentequipmentutilizingutilizing intelligent process controlsintelligent process controls

Analysis and testingAnalysis and testing

Capabilities from all SDSM&T engineering departmentsCapabilities from all SDSM&T engineering departments

The Advanced Materials Processing CenterThe Advanced Materials Processing Center


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AMPSDSM&T

SDSM&T AMP Center FacilitiesSDSM&T AMP Center Facilities

Co-Located Friction Stir and Laser Processing Equipment

Friction Stir

ProcessingCell

Delivery in 3Q02

Laser

ProcessingCell

Delivery in 2Q02


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AMPSDSM&T

DevelopDevelopGame ChangingGame ChangingAdvanced Materials ProcessingAdvanced Materials Processing(AMP) Technologies(AMP) Technologies

PerformPerformCutting EdgeCutting EdgeFriction Stir Processing (FSP) andFriction Stir Processing (FSP) andIntelligent Laser Processing (ILP) Research andIntelligent Laser Processing (ILP) Research andDevelopmentDevelopment

Facilitate Integration of FSP and ILPFacilitate Integration of FSP and ILPDesign SpaceDesign SpaceIntoIntoProcessing SpaceProcessing Space

EstablishEstablishInterdisciplinaryInterdisciplinaryFSP and ILP Graduate andFSP and ILP Graduate andUndergraduate Educational OpportunitiesUndergraduate Educational Opportunities

Enable FSP and ILPEnable FSP and ILPTechnology TransferTechnology TransferInto Local,Into Local,Regional and National InfraRegional and National Infra--structurestructure

The AMP Center Goal is to:The AMP Center Goal is to:


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AMPSDSM&T

MultiMulti--Axis Friction Stir ProcessingAxis Friction Stir Processing


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AMPSDSM&T



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AMPSDSM&T


Large, sevenLarge, seven--axis working areaaxis working area

X (39), Y (118), Z (48)X (39), Y (118), Z (48)

Head: 30Head: 30

oo

pitch and 15pitch and 15

oo

rollroll Forge (1.25), Pin (1.25)Forge (1.25), Pin (1.25)

Robust CapabilitiesRobust Capabilities

20,000 lbf (max)20,000 lbf (max)

2000 rpm (max)2000 rpm (max)

50 ipm (max)50 ipm (max)

315 ft315 ft--lbf torque (max)lbf torque (max)

Position and load controlPosition and load control

Precision (.08% F.S.) pressurePrecision (.08% F.S.) pressure

and position transducersand position transducers Fixed, Adjustable, andFixed, Adjustable, and

MTS Patented Self ReactingMTS Patented Self ReactingPin Tool modesPin Tool modes


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AMPSDSM&T

MTSMTS--ASRPTASRPT

Trunnion Pin

Adjustable Self-ReactingPin Tool

Actuator Housing

Actuator forAdjustable Pin


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AMPSDSM&T

The MTS Design Offers Unique CapabilitiesThe MTS Design Offers Unique Capabilities

Better than +/Better than +/--50 lbf load control capability over the full 20,00050 lbf load control capability over the full 20,000pound load rangepound load range

Made possible by MTS HydroMade possible by MTS Hydro--static Bearing technologystatic Bearing technology Sufficient Forge Load for thick section (1) butt jointsSufficient Forge Load for thick section (1) butt joints

Repeatable loads for thin gage (0.040) lap jointsRepeatable loads for thin gage (0.040) lap joints

Forge Load and Adjustable Pin actuators are integrated withiForge Load and Adjustable Pin actuators are integrated withinnthe Weld Headthe Weld Head

Maintains perpendicular forge load in vectored x, y, z, pitch anMaintains perpendicular forge load in vectored x, y, z, pitch and rolld rollspacespace

Critical requirement for complex contour joints in either fixeCritical requirement for complex contour joints in either fixed pin ord pin oradjustable pin modesadjustable pin modes

The MTS ASRPT Head design specifically allows for SelfThe MTS ASRPT Head design specifically allows for SelfReacting Pin Tool mode for complex contour configurationsReacting Pin Tool mode for complex contour configurations

Thin plate lap and butt joints over the full envelopeThin plate lap and butt joints over the full envelope

Thick plate butt joints over a modified envelopeThick plate butt joints over a modified envelope


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AMPSDSM&T

Intelligent Laser ProcessingIntelligent Laser Processing Increasing industrial usageIncreasing industrial usage

Cutting, welding, forming and bendingCutting, welding, forming and bending

Heat treatment and annealingHeat treatment and annealing

MicroMicro--machining and drillingmachining and drilling

Ideal for surface treatmentsIdeal for surface treatments

Cladding, coating, and alloyingCladding, coating, and alloying

Shock peening and dimplingShock peening and dimpling Surface transformationsSurface transformations

New materials developmentNew materials development

Net shape manufacturingNet shape manufacturing Direct Metal Deposition (DMD)Direct Metal Deposition (DMD)

Reclamation of scrap partsReclamation of scrap partsCourtesy LENS Program


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AMPSDSM&T

Laser Processing EquipmentLaser Processing Equipment

Trumpf Nd:YAG Laser (3kW)Trumpf Nd:YAG Laser (3kW)

Fanuc M16i robot and controllerFanuc M16i robot and controller

60 reach and 40 horizontal stroke60 reach and 40 horizontal stroke

Rotary tableRotary table

Two (2) Metal Powder FeedersTwo (2) Metal Powder Feeders

Shielding and flow assist gasesShielding and flow assist gases

Labview Process ControllerLabview Process Controller

Hand Coded/ Teach PendantHand Coded/ Teach Pendant

Process Sensors and ControlsProcess Sensors and Controls Geometry, temperature, andGeometry, temperature, and

positionposition


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AMPSDSM&T

Powder FeedersPowder Feeders


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File: AMPDIR-02-AMP-Rev A

Date: June 2002Page: 14


AMPSDSM&T

Laser Optics and Control SystemLaser Optics and Control System


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AMPSDSM&T

Unique LaserUnique Laser--Powder Calibration SystemPowder Calibration System


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AMPSDSM&T

Initial Trials CompletedInitial Trials Completed

1.0


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AMPSDSM&T

Laser Processing of Graded AlloysLaser Processing of Graded Alloys


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AMPSDSM&T

Direct manufacturing of high quality

titanium alloy structures withouttools, dies or forms.

Material: 3,000 lbs 200 lbs

Machining: 500 hours 100 hours

Time: 12 months 2 monthsTooling: $ Millions $ Minimal

Overall cost savings of 20-50%

Conventional Additive

IntroductionLaser Additive Manufacturing


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AMPSDSM&T

Direct Metal DepositionDirect Metal Deposition

http://www.aerometcorp.com/


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AMPSDSM&T

Product Design and Development UsingProduct Design and Development UsingDirect Metal DepositionDirect Metal Deposition

Highly Suitable

Less Suitable

Part GeometryAffects Benefits of

Producing by DLD


Check

http://www.aerometcorp.com/applicat.htm

For Applications Videos


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AMPSDSM&T

Benefits of Direct Laser DepositionBenefits of Direct Laser Deposition



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AMPSDSM&T

Keel Machining Trials

Preform

Model

Completed

Preform

Machining

Process

Final Part

100


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AMPSDSM&T

36 inches

Preform Model

Machining

Preform

Metals Affordability InitiativeLaser Additive Manufacturing

Ti-6Al-4V F-15 Pylon Rib

Part Being Machined


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AMPSDSM&T

Laser Processing Research OpportunitiesLaser Processing Research Opportunities

GradedAlloys

PartsRefurbish

LaserWelding

LaserCutting

LaserMicro

Machining

LaserForming

LaserHardening

LaserCladding

LaserDeposition

LaserDrilling

LaserProcessing

ProcessSensors

NewMaterials

IntelligentProcess

ThermalModels

ProcessModels

PhaseTransform

Models

MaterialsProperties

CAD/CAMInterface

Non-DestructiveInspections

PropertyModels

EfficientDesigns


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AMPSDSM&T

The NSF Friction Stir Processing(FSP) Industry /University

Cooperative Research Center

(I/UCRC)

AMPSDSM&T

(Proposed)


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AMPSDSM&T

I/UCRC - NSF FSP Center

The Win-Win Solution to Integrated AdvancedMaterials Processing Technology Developments

UNIVERSITY

INDUSTRY

INDUSTRY

GOVERNMENT

GOVERNMENT

AMPSDSM&T

The Four Top FSP Academic Institutions Join Together in a

Symbiotic Relationship to Develop the NSF AdvancedMaterials Processing Center

University of South Carolina

Brigham Young University University of Missouri - Rolla

South Dakota Schoolof Mines and Technology


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AMPSDSM&T

I/UCRC NSF FSP Center

The Win-Win Solution Brings TogetherVast FSP Academic Research Experiences

AMPSDSM&T

Coupled Thermo- Mechanical-Force Models

Metal flow and defect formation

Temperature distributions Constitutive relationships

Process Parameters vs. Properties

Room, elevated, and cryogenic strength

Fracture, fatigue, and corrosion

Residual stress and texturing

Process Parameters vs. Microstructure Evolution

Time, temperature, and strain rates

Active heating and cooling

Pin Tools Materials and Pin Tool Designs

FSP of aluminum, titanium, steel, copper, nickel,

MMCs Fixed, retractable, bobbin and self-reacting tools

Post Friction Stir Processing

Post FSP heat treatment and abnormal grain growth

Superplastic forming and spin forming

South Dakota

School of Mines

University ofSouth Carolina

Brigham Young

University

University of

Missouri- Rolla


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AMPSDSM&T

I/UCRC NSF FSP Center

The Win-win Solution Provides for BothStrategic an Operational Planning

AMPSDSM&T

Mission Statement:

To advance the field of Friction Stir Processing science and engineering through research,

education, and technology exchange among academic, industry, and government

Friction Stir Processing (FSP) Science and Engineering Fields:

Friction Stir Joining

Fusion Weld Replacement

Friction Spot Joining

Rivet Replacement

Post- Friction Stir Processing

Heat Treatment, Superplasticity, Forming, Machining, Corrosion Protection

Efficient Structural Designs


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AMPSDSM&T

SummarySummary The AMP Center Offers A Unique Opportunity for SDSM&T toThe AMP Center Offers A Unique Opportunity for SDSM&T to

Develop and Transfer Game Changing TechnologiesDevelop and Transfer Game Changing Technologies

SDSM&T AMP Center Technology Focus AreasSDSM&T AMP Center Technology Focus Areas Large, MultiLarge, Multi--Axis Friction Stir ProcessingAxis Friction Stir Processing

Design SpaceDesign Spaceintegration intointegration into Processing SpaceProcessing Space

Intelligent Laser Processing and Direct Metal Deposition of MateIntelligent Laser Processing and Direct Metal Deposition of Materialsrials

FSP and ILP/DMD synergistic projectsFSP and ILP/DMD synergistic projects

The AMP Center will provide to University, Industry, andThe AMP Center will provide to University, Industry, andGovernment FSP and ILP/DMD researchers a coGovernment FSP and ILP/DMD researchers a co--locatedlocatedState of the Art facility for sponsored research projectsState of the Art facility for sponsored research projects

The AMP Center will Provide SDSM&T Students with Hands OnThe AMP Center will Provide SDSM&T Students with Hands OnPractical Experience with Two Emerging Advanced MaterialsPractical Experience with Two Emerging Advanced MaterialsProcessing TechnologiesProcessing Technologies

Increased Marketable SkillsIncreased Marketable Skills

Documents

MTS Presentation