Improving Global Quality of Life

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Furthermore, in the field of dissimilar combinations of metallic, ceramic and carbon-carbon materials, the following areas are creating challenges. Technologies for joining (welding) the above materials by using new pulsed heating methods, electromagnetic or mechanical effects, and hybrid solid-state joining processes. New welding consumables in the form of films, foils, powders and pastes, including multilayer foils, capable of entering into reaction of high-temperature synthesis of intermetallic phases in local volumes (spaces). Building of new types of structures from materials with a minimal specific weight, i.e. foam materials, sandwiches, dissimilar compositions, volumetric billets of typical shapes (cylinders, cones, hemispheres), ribbed panels and panels with cavities. Building of armoured and fireproof welded structures through a combined use of dissimilar materials and their joining methods, as well as compact transformable billets, which can be transformed into large-volume structures (tanks, compartments, habitable rooms, etc.). Manufacture of Thermal Protection Systems: Near- and trans-space structures require efficient thermal protection systems (TPS) to deal with reusable, multi-re-entry vehicles. The selection and combination of materials for maximum thermal, structural, and weight performance is crucial. The joining technology that is flying today is over thirty years old. Improvements in materials joining methods are enabling technologies for advanced flight concepts. Welding, brazing, soldering, adhesive bonding, and NDE are all pertinent to this field. Repair: Manufacture, repair, and overhaul continue to be a major driver of joining technology innovation in the aerospace industry. Repair technologies are driven by two competing factors; low metallurgical damage to the substrate and high deposition rates. These features, however, are generally mutually exclusive. This has driven technology innovations such as laser powder buildup, cold metal transfer and cold spray. There is also a push towards near net shape repair. This is attaching pre-formed repair elements, reducing the expense of post-deposition machining. Reducing material usage: Improving material buy-to-fly ratios, is a key element in reducing the overall costs of manufacture. To this end, welded components are increasingly replacing those machined out of single blocks of materials. Generally, two penalties are paid for replacing a fully machined component with a welded one. The first is loss of properties in the weld and heat affected areas. The second is geometric stability of the final part. New processes, better process control, better predictive capabilities, etc. will all be necessary to address this new generation of welded components. Implementation of low cost manufacturing technologies: Reducing the overall costs of manufacture continues to be a major driver for technology innovation in the aerospace industry. To this end, there is increasing interest in standardisation of parts, and subsequent increases in manufacturing volumes for those components. Higher volumes permit economies of scale. This has placed focus on higher productivity joining processes. Higher productivity joining ranges from increased deposition rates with existing processes, to the use of newer approaches. In this regard, laser processing, resistance welding, etc., with their inherent advantages in higher production volumes, will see increasing use in aerospace construction. Development of novel solid-state processes: Manufacturability of hardware through novel solidstate welding processes offers distinct advantages to the aerospace industry reducing buy-to-fly ratios and production costs. Ultrasonic additive manufacturing (UAM) is one such technology based on solid-state welding, joining successive layers of material to produce near net shape hardware. Producing hardware in this fashion requires minimal material consumption while producing highly accurate components. Fabrication of such hardware also allows for the development of smart 150 Improving Global Quality of Life Through Optimum Use and Innovation of Welding and Joining Technologies
9 Needs and challenges of major industry sectors for future applications structures where reactive embedded materials can serve as sensing devices and/or actuators. Advancements within this technology will permit fabrication of hardware with advanced materials such as titanium, stainless steels, and nickel based alloys, increasing widespread use. Additive manufacturing: A suite of potential tools for additive manufacturing is being qualified through a five stage process for certification for their use in aerospace markets. Leading processes are laser/powder and laser/wire, as well as electron beam free form fabrication (EBFFF). Much work remains to be done to qualify these and other processes (e.g. model and control distortion) for implementation into end use applications which include titanium alloys, stainless steels, and nickel based alloys, with particular emphasis on increasing the buy-to-fly ratios for expensive and long lead time articles such as titanium forgings, and increasingly expensive high alloy materials. High-efficiency Al and Mg alloys: Welding and joining of micro and nano-sized composite materials (with insoluble particles; with fibres and nets; multilayer macro-sized; multilayer micro- and nanosized). Heat-resistant materials: Building of new generations of aircraft and rocket engines will require development of new processes for joining advanced materials and new specialised equipment. Widening of applications of nickel-base alloys with single crystal structure, heat-resistant and radiation-resistant alloys, refractory metals, ceramic and cermet composite materials can be anticipated. It should be planned to work on making structural components of engines by using new welding methods, as well as manufacturing them by micro-layer growing from liquid-vapour matrices. New structural materials will be developed based on optimisation of their weldability. Elaboration of the new principles for decreasing degradation of welded joints in operation of structures will provide their long service life and high performance. 9.19 Welding in space Predicted development and challenges of welding and related technologies for space applications can be summarised as following: Welding equipment: Electron Beam (EB) and Laser Beam (LB) welding processes, EB brazing, laser brazing, deposition of coatings using EB and LB heating, equipment developments for mechanised and manual processes. Auxiliary equipment: Manipulators, tilters, robotised welding systems. Power supplies: Solar energy converters, power generation (life support low-power reactors), thermoelectric converters. Moon exploration prediction: 1. Utilisation of transformable large-size welded shell structures for construction of long-term lunar outposts (LLO). 2. Application of EB and laser technologies for carrying out different operations on the Moon: Assembly and damage control operations using welding, brazing and coating. Processing of moon rock to produce oxygen. Melting of moon rock to produce different metallic and non-metallic materials. Floating-zone melting to produce super pure perfect semiconductor materials, composite materials and intermetallics. Through Optimum Use and Innovation of Welding and Joining Technologies Improving Global Quality of Life 151
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Improving Global Quality of Life Th
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Foreword Dr Baldev Raj Mr Chris Sma
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In alphabetical order (Continued) D
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6.3 Job, skill, career and competen
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9.6.3 Welding processes and challen
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Executive summary “ Welding is an
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Editors’ Preface Improving Global
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Scope and objectives 1 an important
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Welding industry 2.in the world 2.1
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2.2 Today’s welding industry and
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2 Welding industry in the world IIW
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3.welding Signifi cance of and join
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3.3 Welding and joining in sustaina
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An example of the value of welding
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16 Improving Global Quality of Life
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4. Needs and challenges in welding
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Welding thick walled steel componen
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The trend towards light-weight desi
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Up-to-date, titanium alloys have be
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Needs for weight reduction in aircr
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Finally, testing of welds will be e
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As another most important item, the
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In order to make the developments i
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Reduction and/or elimination of dis
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5. Needs and challenges in welding
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The productivity in EB welding has
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The potential applications are for
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5.2 Higher automation, productivity
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In submerged arc welding one can re
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From a practical perspective, the n
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Acceptance levels are not included
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5.5 NDT and structural health monit
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IIW can help companies to get their
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6. Needs and challenges in health,
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welder against Cr6 is a very import
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is considerable national concern fo
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important in meeting needs with res
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7. Legal codes, rules and standardi
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In national or regional legal codes
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7.4.2 Optimum laws Laws applying in
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IIW needs to help ISO and others cl
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structures. It is unlikely in the s
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8. Needs and challenges for global
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infrastructure to develop multiple
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Table 8.1 Key actions and key activ
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9.7.1 Hot topics ..................
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New discoveries tend to be in deepw
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Proved reserves at end 2004 Trillio
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easily weldable, the life expectanc
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9.1.3 Hot topics Reducing negative
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Following these codes assures initi
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9.1.5 Hot topics Development and up
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9.1.8 Power - Renewable Rising fuel
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9.2.2 Production using joining tech
Page 114 and 115: still sometimes an unanswered quest
Page 116 and 117: 2. To an increasing extent, joining
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Page 120 and 121: 9.3.2 Hot Topics The following issu
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Page 124 and 125: technology based on the existing pi
Page 126 and 127: general investment climate, includi
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Page 130 and 131: Globalisation: PEI is operating in
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Page 134 and 135: On the other hand, when looking at
Page 136 and 137: 9.7.2 Welding in the minerals proce
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Page 142 and 143: implementation of smart systems. In
Page 144 and 145: 9.9.2 Hot topics Raising and enforc
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Page 152 and 153: 9.13.2 Preheat Preheating is carrie
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Page 156 and 157: Portable power: In the Portable Pow
Page 158 and 159: the HRI report which accounted for
Page 160 and 161: 9.16.2 Joining live tissues and coa
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Page 166 and 167: 9.20 Small and medium enterprises
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Page 174 and 175: 10.4 Long-term strategic agenda IIW
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Page 180: IIW White Paper - Edition 2012 ISBN
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