Seventh aiCAMstir Meeting, 26 January 2023: Difference between revisions
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Use coatings | Use coatings | ||
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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|]] | [[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]] | ||
[[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|]] | [[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)]] | ||
[[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|]] | [[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, | ||
[[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|]] | Variation LHS-RHS: robotic and manual or differently programmed, | ||
[[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|]] | End-crater parked away from the highly stressed zone, | ||
[[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|]] | Burn-in at the weld start, | ||
[[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|]] | Consistency and accuracy are required, | ||
[[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|]] | MIG welding of aluminium is more difficult than MAG welding steel, because you cant see the temperature, | ||
[[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|]] | Production ramp-up is complicated and expensive]] | ||
[[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|]] | [[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, | ||
[[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|]] | 2 Fanuc robots, | ||
[[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|]] | 2 MIG welding kits, | ||
1 positioner, | |||
Simple automated hydraulic fixtures]] | |||
[[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, | |||
2 OTC FD-B6L, | |||
1 OTC FD-V166]] | |||
[[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]] | |||
[[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]] | |||
[[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, | |||
The majority of long range BEVs in current production worldwide use aluminum as the main material for the battery enclosure, | |||
However, dissimilar material combinations are getting increasingly attractive]] | |||
[[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, | |||
Expensive tooling for die casting of aluminium, | |||
Most OEMs have excellent foundries and want to keep their staff employed, | |||
Tray and Total Assembly made from Plastics, | |||
Battery Tray: 72 kg vs. 43 kg: Δ 29 kg (weight saving by using plastic), | |||
Total Assembly 489 kg vs. 427 kg: Δ 62 kg (cost saving by using plastic)]] | |||
[[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, | |||
According to a rule of thumb, the cost of FSW-specific aluminium 6000 series extrusions is about LME + Premium + 1.0-1.2€/kg]] | |||
[[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, | |||
Labour, maintenance and training, | |||
Factory building, | |||
Sawing and collating of extrusions, | |||
Pressure testing, | |||
Adhesives and paints, | |||
Material storage and handling, | |||
Development, crash and fire testing]] | |||
[[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, | |||
An empty battery tray costs approx. 480 €, | |||
FSW is very cost effective: 0.69 €/m, | |||
The material costs for the aluminium extrusions are the main cost factor, | |||
Dissimilar material combinations are often beneficial]] | |||
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Revision as of 11:14, 27 January 2023
The Seventh aiCAMstir Meeting was held online on 26 January 2023 with 32 attendees.
Agenda
The agenda of the 90 min long on-line meeting was as follows:
- Welcome and introduction (2-3 sentences each)
- Development of a new stitch friction stir welding gun and mechanical behavior of intersecting stitch welded AA 6016-T4 sheets. Dominik Walz, MPA Stuttgart, Germany (20 min + 5 min questions)
- Effect of FSW tool geometry on the joint quality of AA2024-T3/AA7075T6 joints in butt configuration. Reza Beygi, INEGI, Porto, Portugal (20 min + 5 min questions)
- Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers. Stephan Kallee, AluStir, Germany (20 min + 5 min questions)
- Collaborative projects, organisational comments and date of next meeting (25 May 2023). Mike Lewis (FTS Engineering Answers Ltd)
Presentations
Development of a new stitch friction stir welding gun and mechanical behavior of intersecting stitch welded AA 6016-T4 sheets. Dominik Walz, MPA Stuttgart, Germany
Effect of FSW tool geometry on the joint quality of AA2024-T3/AA7075T6 joints in butt configuration. Reza Beygi, INEGI, Porto, Portugal
Machine investment cost and tool wear of friction stir welding of battery trays of compact crossovers. Stephan Kallee, AluStir, Germany
A video recording of this online meeting is available via the following link:
Recording of the Seventh aiCAMstir Meeting (Total: 1:45 h, the first presentation starts at 0:10:16 h) |
Literature
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Next meeting
We want to invite you to attend the Eight online aiCAMstir Meeting on using artificial intelligence in Computer Aided Manufacture of friction stir welds. The meeting will be held on Thursday, 25 May 2023, 16:00 - 17:30 (London), as shown on upcoming events.
Please contact stephan.kallee@alustir.com, if you want to attend the meeting and/or if you want to participate in the project.