ISTIR™ Friction Stir Welding Solutions L Ensure the Successful Transition of FSW from Your Laboratory to Your Production Floor

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ISTIR™ Friction Stir Welding Solutions l Ensure the successful transition of FSW from your laboratory to your production floor. 100-111-781_istir 7/8/03 2:08 PM Page 2

R EALIZE THE P ROMISE OF F RICTION S TIR W ELDING

such factors as budgetary limitations, time constraints, and your organization’s level of FSW process development expertise, You have recognized the promise of friction stir welding (FSW)- you must choose a realistic approach that is appropriate to your specific circum- the potential benefits of this rapidly maturing technology are stances – a faulty strategy will prove costly numerous: reduced assembly costs, higher quality joining, and time-consuming.

stronger and lighter joints, less pollution, and significantly MTS: A Uniquely Qualified reduced production cycle times. Bringing FSW to the production floor, FSW Solution Provider however, is neither a simple nor risk-free As the world’s leading provider of preci- endeavor. Successfully implementing this sion force and motion control systems and rapidly evolving process requires consider- recognized innovator of cutting edge FSW able process expertise, a sound develop- technology, MTS is uniquely qualified to ment plan, and reliable, technologically help you mitigate these risks and formu- advanced equipment. Carefully weighing late a sound FSW process development strategy. We can provide you with the level of FSW process development expertise that you require to understand the full benefits of this promising technology, explore its feasibility for a given application, and create and implement a sound process development strategy that meets your organization’s unique needs within the constraints of available technology, time and budget. Your solution may entail the formulation and implementation of a detailed FSW process development plan, the delivery of one of our proven development systems, a transfer of technology, or merely the performance of a feasibility study. No matter what your needs, MTS is the best-qualified organization to ensure the successful transition of FSW from your laboratory to your production floor.

MTS Systems Corporation is the world’s leading provider of precision force and motion control systems and a recognized innovator of cutting edge FSW technology.

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ISTIR Friction Stir Welding Development Model From our deep understanding of complex FSW processes and tooling gained from a wide variety of development efforts we have developed Intelligent Stir Welding for Industry and Research (ISTIR), an FSW development model that employs an inter-organizational team approach and a progressive three-phase program to put FSW into production as efficiently and cost-effectively as possible. Employing the ISTIR model, we can equip you with the world’s most versatile and reliable We employ a progressive three-phase pro- FSW development systems and, if neces- gram to help you put FSW into production sary, provide additional levels of guid- as efficiently and cost-effectively as possible. ance to ensure the successful transition of FSW from your laboratory to your production floor.

The ISTIR model’s progressive, phased Collaborative Team Approach controls, and process knowledge required development program is based upon a One of the primary strengths of the ISTIR to move the friction stir welding process best practices model developed by MTS model is its team approach to friction stir past the laboratory stage and into produc- through decades of producing complex, welding development, which emphasizes tion. Team members from both organiza- turnkey systems. Adapted for friction stir the free and efficient flow of ideas and tions are encouraged to maintain frequent, welding, this program consists of three information. You supply design, analysis, direct contact with their counterparts to phases: Application Assessment, Process materials and process engineering expert- review the various design and manufactur- Development & System Design, and ise specific to your industry, while MTS ing program aspects. Implementation for Production. provides the critical design,

PHASE IPHASE II PHASE III Application Assessment Process Development & System Design Implementation for Production •Customer •Requirements •Design Concept •Weld •Customer Specifications Specifications •Experience Specifications Specifications •Analysis •Analysis •Drawings •Functional

NPUT •Experience •Experience •Experience Specifications I •Experience

System Conceptual Detail Design/ Fabrication/ Process Installation/ Product Requirements Design Certification Preparation Development Activities

•Requirements • Design Concept •Drawings •FSW System •Accepted System Specification •Weld •Specification •Certified Processes •Output Specifications Updates

UTPUT •Process

O Modifications

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V ERSATILE ISTIR FRICTION S TIR W ELDING E QUIPMENT

MTS has developed an array of leading-edge friction stir welding systems capable of providing the advanced capability and versatility required for research, process development, prototyping and production:

The ISTIR PDS (Process Development System) solution is a fully instrumented research system that is capable of simultaneous force-controlled operation of three independent axes (X, Z, and Pin). This system features MTS Adaptable Adjustable Pin Tool (AdAPT™) weld head technology, enabling it to perform self- reacting welds and join materials of varying thickness. The ISTIR PDS can support up to 5 DOF to produce welds with double curvature. The ISTIR PDS has successfully joined materials less than 1mm and up to 40mm in thickness.

The ISTIR PDS Jr. solution is a single-axis system designed to perform linear welds. As a lower cost alternative to ISTIR PDS, this system features many of the same innovations as the PDS solution, such as MTS AdAPT weld head technology. The PDS Jr. has been deployed to perform process research. 100-111-781_istir 7/8/03 2:11 PM Page 5

The ISTIR 10 Gantry is a 5-DOF system capable of producing parts requiring multi-axis welding. This system features MTS AdAPT weld head technology and a 10-ton forge load capacity, which is needed for thicker section welds and hard metals.

The ISTIR Aero system is a 5-DOF system for use with thin-gauge aluminum alloys. Capable of producing high-speed welds of complex contours, this system features data collection of all critical parameters so that Statistical Process Control (SPC) can be used to ensure quality. The system’s control software is compatible with most standard CAM programs. The ISTIR Aero system is also capable of performing basic machining tasks such as drilling, trimming and rough machining. 100-111-781_istir 7/8/03 2:12 PM Page 6

F LEXIBLE ISTIR GUIDANCE

Early in the design cycle of the Following the ISTIR development model, Eclipse 500 jet aircraft, Eclipse Aviation Eclipse and MTS assembled a powerful Corporation partnered with MTS to team of aircraft design and FSW process explore the efficiency and reliability of development talent. Eclipse supplied the using friction stir welding in the produc- critical design, analysis, materials and tion of primary aircraft structures. By suc- process engineering expertise to address Solution Profile: cessfully integrating FSW into the produc- the service-life details of the aircraft; and Eclipse Aviation Corporation tion of the Eclipse 500 the company could MTS supplied the design, controls, and eliminate 60 percent of the rivets from process expertise needed to move the We can work closely with you from the out- the aircraft’s design, resulting in reduced FSW process past the laboratory stage and set, guiding you through application assess- assembly costs, better quality joining and into production. Using the MTS in-house ment, process development, and implemen- stronger and lighter joints. Because FSW ISTIR PDS, the team produced thousands tation for production to ensure that the is significantly faster than other structural of development welds & prototype panels process you implement and the equipment joining processes the aircraft’s cycle time in support of the FAA certification effort. you deploy are the best possible match for in production would decrease drastically your unique FSW application. as well. This productive collaboration yielded the world's first production application of friction stir welding technology for the The ISTIR Aero system represents the world’s first fabrication of primary aircraft structures, production application of friction stir welding technol- the ISTIR Aero system. This 5-DOF system ogy for the fabrication of primary aircraft structures. features MTS AdAPT weld head technology and is capable of producing high-speed welds of complex contours in thin-gauge aluminum alloys. The system’s control software is compatible with most standard CAM programs, and additional sensors enable data collection of all critical parameters so that Statistical Process Control (SPC) can be used to ensure weld quality.

Eclipse Aviation has since used the system to manufacture many of the skin assem- blies on the Eclipse 500. The successful joining of these first components represents a major step forward in the valida- tion and certification of friction stir welding in the assembly of this aircraft.

Photos courtesy of Eclipse Aviation Corporation

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The Universal Weld System (UWS) is Solution Profile: capable of producing Universal Weld System precise, high quality friction stir welds on We can play a supporting role, augmenting complex curvature your in-house process development expert- components. ise in whatever consultive capacity you require to ensure that you deploy the best possible equipment for your unique FSW application.

When Lockheed Martin Space Systems Prior to enlisting MTS expertise to produce NASA’s Auto-adjustable Pin Tool for Company needed a manufacturer for its the system, Lockheed Martin engineers Friction Stir Welding (U.S. Patent innovative universal friction stir welding had performed much of the critical appli- 5,893,507), for which MTS has signed system it turned to MTS Systems cation assessment and process develop- a co-exclusive license agreement. Corporation. The system’s initial applica- ment work themselves — what remained tion would be to join full size test panels was to apply what they had learned to In December of 2002 the National Center representative of the domed section of a design and fabricate the system. Applying for Advanced Manufacturing (NCAM) reusable cryogenic tank, which is similar the flexible ISTIR development model awarded MTS several contracts to produce to the external fuel tank of NASA’s space to accommodate a more supporting role, the UWS to support its Complex Curvature shuttle. From the outset Lockheed Martin MTS teamed with Lockheed Martin experts Friction Stir Welding Risk Reduction understood that successfully applying fric- to address the remaining design and fabri- Program. NCAM is a partnership between tion stir welding to such large and com- cation challenges efficiently and cost-effec- NASA, the State of Louisiana, the plex geometric shapes would demand the tively. The product of this collaboration University of New Orleans and Lockheed simultaneous control of both position and was the Universal Weld System (UWS), a Martin Corporation to explore advanced load within highly accurate and precise 5-axis friction stir welding system capable manufacturing technologies for NASA’s tolerances. As the world’s leading supplier of producing precise, high-quality friction Next Generation Launch Technologies of complex motion systems and proven stir welds on complex curvature compo- Program. NCAM will operate and maintain innovator of advanced FSW technology, nents. This leading-edge system features the UWS at the Michoud Assembly Facility MTS was the logical choice to design and the world’s largest FSW working envelope in New Orleans. manufacture such a system. and advanced technology based on

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F ORCE & MOTION C ONTROL E XPERIENCE, TECHNOLOGICAL I NNOVATION

Maintaining optimal pin position, especial- ly in nonlinear applications, is the most daunting obstacle to producing consistent, MTS has a history of innovation evidenced by the patenting of high-quality FSW joining. As a pioneer and leader in precision force and motion con- a number of technical advances for force and motion control trol, MTS has embraced this challenge, systems, including the self-reacting weld technique. developing sophisticated new load control technologies and system innovations that have proven to be robust and reliable in Our commitment to becoming the world’s both linear and nonlinear applications. leading FSW equipment supplier is exem- plified best by our aggressive technology Unrivaled Process Control: development efforts, which have already MTS has achieved the seamless integration yielded several innovative breakthroughs of innovative mechanical, electrical and and continue to push the state-of-the-art. software systems to deliver unrivaled control over all aspects of friction stir welding We recognized early on that the precise processes. Advanced MTS application soft- control of force and motion is pivotal to ware and powerful TestStar™ controllers realizing the full promise of FSW. allow you to: Integrate CAD/CAM packages into the process to accurately track weld paths Perform offline CAD/CAM planning Accurately acquire and manage weld data Measure and control key process parameters to achieve six-sigma weld quality Record all welding parameters for use in Statistical Process Control (SPC) programs

MTS has developed sophisticated new load control technologies and system innovations that have proven to be robust and reliable in both linear and nonlinear FSW applications.

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Advanced Tooling & Techniques: equipment. These same MTS FSW tooling MTS drives the state-of-the-art of FSW innovations will enable you to: tooling with innovative pin tool and forge Employ three welding modes (tooling load control technologies. Utilizing a highly types) - fixed, adjustable, and self-reacting - accurate, low-friction independent forge to accommodate both linear and complex, actuator (patent pending) and advanced non-linear contour weld configurations Adjustable Adaptable Pin Tool (AdAPT) Switch between welding modes weld head technology, MTS was able to on-the-fly produce the first fully instrumented friction Maintain a controlled, perpendicular stir welding system capable of performing forge load in vectored x, y, z, pitch load-controlled welds along multiple axes. and roll space Additionally, the AdAPT packaging allows Produce quality joints in materials from the weld head to be integrated into cus- 1mm to over 40mm thick tom configurations or mounted to existing Operate in up to 5 degrees-of-freedom.

Fixed Pin Tool Section of Friction Stir Weld Adjustable Pin Tool Section of Friction Stir Weld Self-Reacting Pin Tool Section of Friction Stir Weld

Welding Welding Welding Direction Direction Direction

Pin Motion Pin Motion Pin Motion

Moving Pin Tool Section of Friction Stir Weld

Welding Depth

Pin Motion Welding Direction

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E XPERIENCED AND I NNOVATIVE FSW DEVELOPMENT T EAM

challenges of providing effective FSW solutions. And as this group ventures further into the growing array of potential MTS has an outstanding team of experienced FSW and manu- FSW applications the innovation continues, as evidenced by such recent technical facturing process experts ready to help you successfully plan advances as: and execute your FSW process development strategy - some team The ability to produce double curvature welds and the welding members have been working on this technology since the initial of tapered materials TWI group sponsored project. Real time process sensors for the intelligent processing of materials Leveraging nearly 40 years of MTS design The ability to weld high temperature and manufacturing expertise, this team has alloys fielded solutions to some of the world’s most challenging test and manufacturing Worldwide FSW Leadership: problems. Through decades of providing In addition to our in-house development innovative force and motion control equip- efforts, MTS plays a leading role in foster- ment they have gained unparalleled ing the worldwide development of FSW expertise in the design and implementa- through numerous teaming efforts with tion of force and motion sensors, data many active participants in the friction stir acquisition and control systems, and force welding industry, government, and acade- and motion actuating components – tech- mia. The following collaborative efforts nology that is crucial for overcoming the have produced several successful system configurations to fulfill a broad array of production applications. University of South Carolina Lockheed Martin Eclipse Aviation Corporation South Dakota School of Mines & Technology Institute de Soudure

We have also secured several licensing agreements to augment our FSW development capabilities and have patented a number of leading edge technologies. TWI Machine Supplier License for Friction Stir Welding (U.S. Patent 5,460,317 & 5,813,592)* Self-reacting Welding Head (U.S. Patent 6,199,745) Co-Exclusive NASA License for Adjustable Pin Tool (U.S. Patent 5,893,507) Independent Forge Actuator (Patent Pending) * International patent numbers are available upon request

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MTS Corporate Advantages MTS Systems Corporation is a global provider of innovative hardware, software, and know-how that enables our customers to produce higher quality materials, products, and structures more efficiently and cost-effectively. We supply products for determining the mechanical behavior of materials, products and structures – including computer-based testing and simulation systems, modeling and testing software, and consulting services – as well as products for automating manufacturing processes. MTS has a proven track record A key component of our success over the of commercializing new technologies. decades has been our industry-leading, worldwide service organization. Regardless of your size or location, MTS is committed to optimizing your return on your ISTIR system investment. To help you maximize the productivity of your system we offer planned professional maintenance, respon- sive local service and spare parts support, To resolve more complex engineering hands-on training programs, and accredited or process challenges, we field an calibration services. To resolve more com- experienced global consulting team. plex engineering or process challenges, we field an experienced global consulting team. The world relies on MTS for cutting- edge force and motion control technology, technical know-how, and service excel- lence. Can you afford to trust your critical friction stir welding development project to anyone else?

Our industry-leading, worldwide service organization is committed to optimizing the return on your ISTIR system investment.

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F RICTION S TIR W ELDING

Faster, Simpler Process Higher speed joining when compared to automatic riveting and most fusion welding processes Friction stir welding is a promising new welding technique Fewer parameters to control that delivers higher quality joining, faster, more cleanly, and Higher-Quality Joining less expensively than most conventional fusion welding and Solid-state process – zero defects riveting processes. Ability to control process to 6 sigma Consistent weld properties Ability to join aluminum alloys that are Invented by The Welding Institute (TWI) its melting point, allowing the pin to unweldable by fusion welding methods in 1991, FSW is a revolutionary solid-state traverse the weld line. As it does, the Produces desirable microstructures in joining process that combines extruding plasticized work material is transferred the weld and heat-affected zones and forging. Joining occurs when a shoul- from the leading edge of the rotating pin Minimal distortion and less residual dered, profiled pin is rotated and plunged to the trailing edge, leaving in its wake a stress than fusion welding into the joint line between two pieces of solid phase bond between the two work sheet or plate material that are butted pieces. Since the joining process occurs at More Efficient together. Frictional heat is generated a temperature below the melting point of Very low energy consumption between the wear-resistant pin and the the work piece material, FSW has several Requires minimal, if any, consumables work pieces. This heat causes the work distinct advantages over fusion welding: No filler wire required piece material to soften without reaching

More Environmentally Friendly no fumes – no need for bulky and intrusive fume extractors E XPLAINING D ETAIL OF F RICTION S TIR W ELD no noise no spark showers safe – no UV or electromagnetic radiation hazards Sufficient downward force to maintain registered contact

Welding Direction Joint Trailing Edge of the Rotating Tool Leading Edge of the Rotating Tool Retreating Side of Weld

Pin Tool Shoulder

Pin Tool Tip

Advancing Side of Weld

Weld Cross-Section 10 100-111-781_istir 7/8/03 2:19 PM Page 13

L ONGITUDINAL S ECTION OF F RICTION S TIR W ELD

Pin Tool Tip Welding Direction Pin Tool Shoulder

Pre-heat Zone

Initial Deformation Zone

Extrusion Zone

Pin Motion Forging Zone

Cool Down Zone

T ESTIMONIALS:

“The benefits of friction stir welding are “Friction stir welding is a relatively new numerous. It eliminates the need for process that is rapidly maturing and the thousands of rivets resulting in reduced MTS technology is advancing the state of assembly costs, better quality joining and the art. The universal friction stir welding stronger and lighter joints. Because this system will provide an accurate, consis- process is significantly faster than other tent means for implementing convention- structural joining processes we can drasti- al friction stir welding on complex curva- cally reduce the cycle time in production.” ture components.”

Oliver Masefield Paula Hartley Vice President of Engineering Manager, Large Metallic Structures Eclipse Aviation Corporation Lockheed Martin 100-111-781_istir 7/8/03 2:19 PM Page 14

REGIONAL BUSINESS CENTERS SALES AND SERVICE LOCATIONS

THE AMERICAS ASIA/PACIFIC NORTH AMERICA CENTRAL AND AFRICA AND SOUTH AMERICA THE MIDDLE EAST MTS Systems Corporation MTS Japan Canada 14000 Technology Drive ArcaCentral Bldg. 8F Laval, Quebec Argentina Egypt Eden Prairie, MN 55344-2290 1-2-1 Kinshi Sumida-ku Ottawa, Ontario Buenos Aires Heliopolis USA Tokyo 130-0013, Japan Toronto, Ontario Brazil Israel Toll Free 1-800-328-2255 Telephone: 81-3-6658-0901 Windsor, Ontario Sao Paulo Tel Aviv Fax: 1-952-937-4515 Fax: 81-3-6658-0904 Mexico Chile Jordan E-mail: [email protected] E-mail: [email protected] Mexico City Santiago Amman Internet: www.mts.com Monterrey Colombia Kuwait MTS Korea, Inc. United States Bogota Kuwait City 5th Floor, Core Building Akron, OH Costa Rica Morocco EUROPE 8-1 Sunae-Dong, Bundang-Gu Albany, NY San Jose Casablanca Seongnam City, Albuquerque, NM Ecuador Qatar MTS Systems Gyeonggi-Do 463-825, Korea Alexandria, IN Quito Doha 58, rue Auguste Perret Telephone: 82-31-714-7151 Atlanta, GA Peru Saudi Arabia Europarc Fax: 82-31-714-7198 Austin, TX Lima Dhahran 94046 Creteil Cedex E-mail: [email protected] Berlin, NJ Venezuela South Africa France Boston, MA Caracas Johannesburg Telephone: 33 (1) 58 43 90 00 MTS Systems (China) Inc. Celina, OH Tunisia Fax: 33 (1) 58 43 90 01 Building 23, No.481, Charlotte, NC Tunis E-mail: [email protected] Guiping Road Chicago, IL EUROPE United Arab Emirates Shanghai 200233, Cincinnati, OH Dubai MTS Systems GmbH P.R.China Dallas/Fort Worth, TX Belgium Hohentwielsteig 3 Telephone: 86-21-5427 1122 Dayton, OH Brussels 14163 Berlin Fax: 86-21-6495 6330 Denver, CO Leuven ASIA/PACIFIC Germany E-mail: [email protected] Detroit, MI Bulgaria Telephone: 49-30-81002-0 Enfield, CT Sofia Hong Kong Fax: 49-30-81002-100 Fredericksburg, VA Czech Republic Hong Kong E-mail: [email protected] Hollister, CA Brno India Houston, TX Prague Bombay MTS Systems S.R.L. Huntsville, AL France Indonesia Corso Cincinnato, 228/b Huntsville, OK Le Chesnay Jakarta 10151 Torino Los Angeles, CA Paris Japan Italy Loveland, CO Germany Hiroshima Telephone: 39-011-45175-11 Minneapolis, MN Berlin Nagoya Fax: 39-011-45175-00.01 Newark, NJ Delmenhorst Tokyo E-mail: [email protected] Oak Ridge, TN Munich Malaysia Peoria, IL Rastatt Selangor MTS Systems Norden AB Philadelphia, PA Greece People’s Republic Södra Långebergsgatan 16 Phoenix, AZ Athens of China SE-421 32 Västra Frölunda Pittsburgh, PA Hungary Beijing Sweden Research Triangle Budapest Shanghai Telephone: 46 31 68 69 99 Park, NC Italy Pakistan Fax: 46 31 68 69 80 Richmond, VA Pianezza Karachi E-mail: [email protected] San Francisco, CA Torino Philippines Seattle, WA Netherlands Manila MTS Systems Ltd. UK St Louis, MO Amsterdam Republic of Korea Brook House Wichita, KS Gouda Daejon Somerford Court Wilmington, DE Poland Seoul Somerford House Warsaw Singapore Cirencester Portugal Singapore Glos. GL7 1TW UK Amadora Taiwan Telephone: 44-1285-648800 Póvoa De Santa Iria Kaohsiung Fax: 44-1285-658052 Romania Taichung Bucharest Taipei Russia Thailand Moscow Bangkok Spain Barcelona Madrid AUSTRALIA AND Sweden NEW ZEALAND Askim, Gothenburg Switzerland Australia Hallau Melbourne Turkey Sydney Istanbul United Kingdom Northhamptonshire Stroud, Glocester Surrey

MTS Systems Corporation 14000 Technology Drive MTS is a registered trademark, and ISTIR, AdAPT and Eden Prairie, MN 55344-2290 USA TestStar are trademarks of MTS Systems Corporation.

RTM No. 211177