friction_kallee:Layout 1 19/5/08 13:40 Page 2
FRICTION STIR WELDING
structures. If used correctly, the FSW Alstom LHB in Germany makes use of subway rolling stock, and Kawasaki
process has significant potential to reduce prefabricated FSW panels to manufacture Heavy Industries uses friction stir spot
the width of the heat affected zone (HAZ) Copenhagen and Munich suburban trains. welding (FSSW) to attach stringers to roof
and the degree of thermal softening Bombardier Transportation in Derby, UK, panels for the prototype Fastech 360Z
experienced in the weld region. Another uses FSW panels for their Electrostar train. Hitachi was amongst the first train
manufacturers in Japan to recognise the
technical and economic benefits of FSW.
They have delivered FSW vehicles for both
commuter and express trains for use in
Japan and overseas, such as the Class 395,
known as Olympic Javelin, to provide
domestic services on the new UK Channel
Tunnel Rail Link.
Material selection and structural
joint design
Steel and aluminium rail cars both have
their own advantages and limitations, but
an increasing number of vehicles are now
made from aluminium. Alternative grades
of aluminium alloys and joint designs are
constantly being investigated, and the
selection of appropriate materials is
Modern railcar design: mock-up of the Hitachi Class 395 at Ebbsfleet International railway station
governed by the joining method and
structural strength requirements (both
driver for the uptake of this process is its vehicles and for replacement stock for the static and dynamic). In principle, there
combination of cost effectiveness and Victoria Line of the London Underground are many aluminium alloys to choose
good weld performance. The process is network. In Japan, Nippon Sharyo obtains from; however, modern aluminium
energy efficient and also environmentally FSW floor panels from Sumitomo Light railcars are commonly made from
friendly, because it requires no filler wire Metal Industries for the production of complex double-skinned extrusions.
or shielding gas and creates no fumes or Shinkansen trains, Nippon Light Metals Some rolling stock manufacturers claim
ultraviolet rays. A further benefit is that makes use of FSW for the fabrication of that foam-filled double-skin structures
the heat input during the FSW process is
relatively low compared to MIG
welding, therefore reducing the overall
level of component distortion. This stems
from the fact that the FSW process
operates below the melting point of the
material to be joined.
Up to 22m long FSW machines have
been designed, built, and commissioned by
a number of international machine
manufacturers. Several of them are
installed at aluminium extruders and are
used for the production of large panels
and profiles with typical wall thicknesses
from 2.3mm to 6.4mm. The trend is now
towards FSW of more than 16mm thick
structural components of aluminium
rolling stock.
The Scandinavian aluminium
extruders Sapa and Marine Aluminium
were the first in Europe to commercially
apply FSW for the manufacture of
Heavy-duty friction stir welding machine at TWI for welding up to 75mm thick aluminium parts
aluminium panels for rolling stock.
100 EUROPEAN RAILWAY REVIEW
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ISSUE 3
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2008
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