friction_kallee:Layout 1 19/5/08 13:40 Page 4
FRICTION STIR WELDING
ALCAN EXTRUDED PRODUCTS
LARGE PROFILES RAIL&BUS
Friction stir welded side skirt panels are made by Sapa from
double-skinned extrusions and used by bombardier for commuter
and underground trains
forced the weld region into tension, as it is thought occurred
in the Ladbroke Grove accident. The idea was to try and
simulate the welds ‘unzipping’. It was however
recommended that large-scale tests be performed to validate
the results of this preliminary work. The results of this study
are available in the TWI report entitled: ‘Comparison of
friction stir and MIG welding – Preliminary small scale and
dynamic tests’, and can be found on the RSSB website
(http://www.rssb.co.uk/pdf/reports/research/T035_rpt_final.p
df). The main conclusions drawn from this work are
summarised below:
YOUR PARTNER FOR
a73
Friction stir welds have a narrow ductile heat affected
zone (HAZ) surrounding the weld, whilst MIG welds are
LIGHTWEIGHT VEHICLES
surrounded by a wider, softer region. The narrowest
MIG weld HAZ was wider than those of any of the
Our leading position in the production of alu-
friction stir welds tested
minium extrusions and lightweight compo-
a73
FSW specimens tested in tension had higher proof and
ultimate stress values than comparative MIG welds. All
nents combined with our longterm references
fractures occurred in the heat softened regions around and wide range of technical support for cost-
the weld
efficient and ecological solutions for rail and
a73
Full-scale or large-scale testing is required, to establish a
bus vehicles can help you realize sustainable
true comparison between MIG and
products and vehicles for today's and future
FSW joints
market needs.
Further insight was developed within the EC project
Alcan Aluminium Valais SA
ALJOIN, which studied the crashworthiness of joints in
Alcan Extruded Products
aluminium rail vehicles. Within this project Alcan,
Bombardier Transportation, DanStir, NewRail (University of
LP Rail&Bus
Max Högger-Strasse 6, P.O. Box 1812
Newcastle) and TWI worked together to develop an
CH-8048 Zürich, Switzerland
understanding of the issues and develop new joint designs
and welding procedures, to overcome any inherent joint
Tel.: +41 (0)43 497 44 22
Fax: +41 (0)43 497 44 06
weakness. The initial full-scale tests confirmed once again
www.alcan-masstransportation.com
www.alcanextrudedproducts.com
www.europeanrailwayreview.com
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