Leistungen
The LinFric® principle is based on hydraulic instead of mechanic actuation. This concept replaces the expensive mechanical gearboxes, which were used in the first generation of linear friction welding machines. To generate the necessary oil-flow of 750l/min a large hydraulic pump would normally be necessary. For LinFric®, however, energy is stored in hydraulic accumulators which are charged with a comparatively small pump while the work pieces are being clamped.
The hydraulic actuation offers the possibility of using a non-sinusoidal motion of the vibrating workpiece, and the control mechanism allows various waveforms to be programmed, e.g. saw-tooth. Programming of complex frequency and amplitude curves is possible for the friction phase. At the end of the friction phase the amplitude can be reduced to zero, while maintaining or increasing the frequency. A shot bolt mechanism can be used for further increasing the alignment of the workpieces, and to protect the operator against inadvertent movements of the oscillator.
The expensive hydraulic actuator is protected against damage through radial forces by a flexible blade. Hydrostatic bearings are used to enable the oscillation of the carriage. Onto this carriage a versatile clamping mechanism is installed, which was designed to be as light as possible.
The LinFric® machine is controlled by a programmable logic controller and provides means of fuzzy logic parameter monitoring.
http://www.linfric.com
Exploitable results
The LinFric® machine was built to demonstrate the process on full-size blisks of stationary gas turbines or aero-engines. These blisks are discs onto which blades are welded either during production to save raw materials and reduce waste (i.e. swarf during machining) or to repair blisks that have been damaged during manufacture or worn during service.
Initial feasibility studies during the project are related to a representative turbine material 17-4PH. The programme comprises the welding of rectangular specimens with a cross section of 18 x 80mm. A detailed test programme was focused on the assessment of the welds and fitness for purpose decisions.
Future work will be carried out on prototype components after finishing the CRAFT project. Initially the process will be industrialised for blisks of stationary turbines and aero-engines, and simultaneously feasibility studies will be conducted in various materials of automotive components and frames for aircraft.
A prototype LinFric® machine has been built. This machine has been commissioned and tested. It will be used for weldability studies for demonstrations to potential customers and to carry out test work for potential customers. This prototype machine is suitable for welding full size components of up to 1m diameter and weld areas of up to 2000mm2. The health and safety features are representative of those of production machines.
The prototype machine will reside at TWI for a period of five years. This will enable Blacks and Raiser to give potential customers access to the machine. Blacks will sell LinFric® production machines exclusively in the UK and Raiser will sell exclusively in Germany. Both will also sell to the rest of the world.
The prototype machine has been built in such a manner that it can be transported to fairs or on-site demonstrations. It is scheduled to be used for 6-9 months in 2004 at Raiser to allow them to establish the technology, undertake training and carry out test work for potential customers.
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