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| ===<big> ''Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers.'' [[User:Stephan Kallee at AluStir|Stephan Kallee]], [[AluStir]], Germany, start at 1:04:38 h </big>=== | | ===<big> ''Methodologies for Simulation of Friction Stir Welding,'' by Henrik Blicher Schmidt, [http://www.hbse.dk/FSW.html HBS Engineering], Denmark</big>=== |
| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 01.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Stephan Kallee, AluStir: ''Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers'']]
| | [[File:FSW methodologies HBSE aiCAMstir 01.jpg|thumb|left|upright=3.2|alt=Henrik Schmidt, HBS Engineering ApS: Methodologies for Simulation of Friction Stir Welding, 8th aiCAMstir Meeting, 25 May 2023|Henrik Schmidt, HBS Engineering ApS: ''Methodologies for Simulation of Friction Stir Welding,'' 8th aiCAMstir Meeting, 25 May 2023]] |
| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 02.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|VW and Ford: Compact Crossovers, Sandy Munro: „Some really fancy extrusions with some fancy welding and some fancy machining“, „Integrate the battery structure into the vehicle, having the battery and body work together“, Modular approach, Cost optimized materials, joining processes and interfaces]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 03.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact, crossovers|Alu<sup>''Stir''</sup> Battery Tray, 1.3 x 1.7 m floor plate, Made from hollow aluminium extrusions, 14 parallel friction stir welds: 22 m weld length
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| Cut off the start and stop or park the end hole in a suitable place, Benchmarking study is based on producing trays for 200,000 cars per year in Europe, 100 sec per car]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 04.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Quality and Cost: aiCAM<sup>''stir''</sup> Software, The vision is to develop a software-package that adjusts the parameters automatically based on CFD, analytical modelling, parameter monitoring, image analysis and non-destructive testing, aiCAM<sup>''stir''</sup> Ontology, To predict the quality and cost of FSW based on parameters, variables and boundary values]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 05.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Flow Drilling]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 06.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|VW ID.4: Munro and Sabic, Necked 8.8 bolts, stretched by a torque wrench („it would take an act of congress, to change that”), Flow Drill fasteners, Anaerobic serpentine seals, Interlayers against galvanic corrosion]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 07.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Flow Drilling: Weber, System 46,000-48,000 € + 350 kg payload robot, Spare parts, IP 12 „bit“ at 17-20 € for 200,000-300,000 parts
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| Brackets for 500,000-800,000 parts, Fasteners, 2×18 + 2×23 = 82 per car, 0.03, 0.10 or 0.15 €]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 08.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Flow Drilling: Weber and OTC etc]] | |
| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 09.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|FSW (friction stir welding)]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 10.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|FSW: Ideal for Aluminium,
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| Low distortion,
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| Very reliable process,
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| Use high quality extrusions with good tolerances,
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| Use rigid machines with sophisticated force and position control,
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| Good clamping required,
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| To be welded from one side using a mechanical interlock or from both sides simultaneously,
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| Run-on and run-off tabs are possible]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 11.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Gantry, CNC-Cell or Robot? Welding speed > 3m/min (up to 5 m/min) depends on rigidity and pin length.
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| Bespoke FSW machine or converted milling machine?
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| FSW and CNC milling in the same fixture?
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| High performance gantry machines for EV battery trays]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 12.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|FSW Tools: Wear Mechanisms,
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| Adhesion (tribological reactions): pits and notches (scoring),
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| Diffusion (embrittlement and fatigue): shearing off the pin.
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| Recommendations,
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| Avoid notch between pin and shoulder,
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| Use Triflat instead of Triflute,
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| Reduce the rotation speed,
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| Increase pin diameter,
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| Keep shoulder diameter as small as possible,
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| Use harder materials,
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| Use coatings
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| ]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 13.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Three cells with a total of six FSW machines are required for 200,448 cars/year]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 14.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|MIG Welding (metal inert gas welding)]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 15.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Ford Mach-E: Munro: MIG welding,
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| Variation LHS-RHS: robotic and manual or differently programmed,
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| End-crater parked away from the highly stressed zone,
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| Burn-in at the weld start,
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| Consistency and accuracy are required,
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| MIG welding of aluminium is more difficult than MAG welding steel, because you cant see the temperature,
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| Production ramp-up is complicated and expensive]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 16.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Ford Mach-E: Nemak,
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| 2 Fanuc robots,
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| 2 MIG welding kits,
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| 1 positioner,
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| Simple automated hydraulic fixtures]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 17.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|OTC MIG Welding,
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| 2 OTC FD-B6L,
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| 1 OTC FD-V166]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 18.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|2 MIG welding robots]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 19.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Aluminium vs. Plastics]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 20.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Market Segments: Battery enclosure mate-rials of current vehicles,
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| The majority of long range BEVs in current production worldwide use aluminum as the main material for the battery enclosure,
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| However, dissimilar material combinations are getting increasingly attractive]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 21.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Benchmarking: Munro and Sabic,
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| Expensive tooling for die casting of aluminium,
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| Most OEMs have excellent foundries and want to keep their staff employed,
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| Tray and Total Assembly made from Plastics,
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| Battery Tray: 72 kg vs. 43 kg: Δ 29 kg (weight saving by using plastic),
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| Total Assembly 489 kg vs. 427 kg: Δ 62 kg (cost saving by using plastic)]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 22.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|LME (London Metal Exchange): Premiums and Discounts,
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| According to a rule of thumb, the cost of FSW-specific aluminium 6000 series extrusions is about LME + Premium + 1.0-1.2€/kg]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 23.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Cost Comparison: Not included,
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| Labour, maintenance and training,
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| Factory building,
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| Sawing and collating of extrusions,
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| Pressure testing,
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| Adhesives and paints,
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| Material storage and handling,
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| Development, crash and fire testing]]
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| [[File:Stephan Kallee, Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers 24.JPG|thumb|left|upright=3.2|alt=Stephan Kallee: Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers|Benchmarking: Conclusions,
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| An empty battery tray costs approx. 480 €,
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| FSW is very cost effective: 0.69 €/m,
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| The material costs for the aluminium extrusions are the main cost factor,
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| Dissimilar material combinations are often beneficial.<br />
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| The cost calculation procedure and more details on purchasing aluminium extrusions and selecting the joining processes as well as four ''Munro Live'' videos can be found in the following article:
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| Stephan Kallee: [https://www.alustir.com/english/fsw-battery-trays/ ''Cost of FSW of Battery Trays — Benchmarking of Friction Stir Welding and Other Processes for Battery Trays of Compact Crossovers.'']]]
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| == Literature == | | == Literature == |
| * [WAL23] Dominik Walz, Robin Göbel, Martin Werz and Stefan Weihe: Effect of Weld Length on Strength, Fatigue Behaviour and Microstructure of Intersecting Stitch Friction Stir Welded AA 6016-T4 Sheets. https://doi.org/10.3390/ma16020533.
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| * [BYO11] Badarinarayan, H.; YANG, Q.; Okamoto, K. Effect of weld orientation on static strength and failure mode of friction stir stitch welds in lap-shear specimens of aluminium 6022-T4 sheets. Fatigue & Fracture of Engineering Materials & Structures 2011, 34, 908– 920. https://doi.org/10.1111/j.1460-2695.2011.01584.x
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| * [OHH05] Okamoto, K.; Hunt, F.; Hirano, S. Development of Friction Stir Welding Technique and Machine for Aluminum Sheet Metal 261 Assembly- Friction Stir Welding of Aluminum for Automotive Applications (2) -. In Proceedings of the SAE Technical 262 Paper Series. SAE International400 Commonwealth Drive, Warrendale, PA, United States, 2005, SAE Technical Paper Series. 263 https://doi.org/10.4271/2005-01-1254
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| * [HBO06] Hunt, F.; Badarinarayan, H.; Okamoto, K. Design of Experiments for Friction Stir Stitch Welding of Aluminum Alloy 6022- 265 T4 - Friction Stir Welding of Aluminum for Automotive Applications (3) -. In Proceedings of the SAE Technical Paper 266 Series. SAE International400 Commonwealth Drive, Warrendale, PA, United States, 2006, SAE Technical Paper Series. https: 267//doi.org/10.4271/2006-01-0970.
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| * [SVN19] Suresh, S.; Venkatesan, K.; Natarajan, E.; Rajesh, S.; Lim, W.H. Evaluating weld properties of conventional and swept friction stir 272 spot welded 6061-T6 aluminium alloy. Materials Express 2019, 9, 851–860. https://doi.org/10.1166/mex.2019.1584.
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| * [Sat02] Sato, Y.S.; Urata, M.; Kokawa, H. Parameters controlling microstructure and hardness during friction-stir welding of precipitation- 297 hardenable aluminum alloy 6063. Metallurgical and Materials Transactions A 2002, 33, 625–635. https://doi.org/10.1007/s11661-0 29 02-0124-3.
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| * [Rod09] Rodrigues, D.M.; Loureiro, A.; Leitao, C.; Leal, R.M.; Chaparro, B.M.; Vilaça, P. Influence of friction stir welding parameters 300 on the microstructural and mechanical properties of AA 6016-T4 thin welds. Materials & Design 2009, 30, 1913–1921. https://doi.org/10.1016/j.matdes.2008.09.016.
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