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Friction stir welding on the London underground

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Back to Media and Events $8M Saved Following Abington Consultation - Case Study 94 1 Million Pound per Annum Potential Savings Through Project - Case Study 167 100kW Electron Beam Machine for Framatome - Case Study 52 100kW Electron Beam Machine for Framatome - Case Study 52 10X Saving in Material Handling Costs - Case Study 438 15% Increase in Production of Flue Products - Case Study 440 1980s Material - A Question of Fracture Toughness - Case Study 407 20% Reduction in Project Management Costs - Case Study 436 20% Savings in Welding Operations - Case Study 437 A Crushing Reply - Technical Advice Casebook - Case Study 162 A Cut Above the Rest - Especially When It Comes to Titanium - Case Study 35 A Novel Approach to Offshore Wind Power ...But Where and How Much? - Case Study 413 A Novel NDT Technique for Inspecting Offshore Structures A Novel X-Ray Inspection System for Counterfeit Component A Tough Choice - Made Easier by Talking to the Right People - Case Study 381 Abington Work Behind Standards Revision - 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Case Study 415 SAFERAIL Prototypes Minimise Wheelset Failures - Case Study 508 Search for a Welded Solution Ends with Election Beam - Case Study 379 Second Opinion Sets Client's Mind at Rest - Case Study 419 Self-Piercing Riveting - Case Study 151 Self-Piercing Riveting Case Study of Volvo FH12 Truck Cab - Case Study 154 Self-Piercing Riveting for Electric Window Winders - Case Study 157 Self-Piercing Riveting of Sunroof Framework - Case Study 156 Serious Savings from Service Assessment - Case Study 223 Shallow Cracks Help! - Case Study 74 SimCoDeQ - Process Monitoring of Composite Materials Manufacturing Simulation of Roll Cage Manufacture - Case Study 201 Simulation Tests Robot Feasibility - Case Study 47 Small Sample Analysis Solves a Problem - Case Study 73 Software for Plant Inspection Analysis - Case Study 194 Software to Predict Distortion and Improve Fatigue SOIMON – Fast and Reliable Technology for In-Situ Soil Inspection - Case Study 608 Solder Materials for use in 'Down Hole' Data Loggers - 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Case Study 525 Swedish and American Conferences Joined by Friction Stir - Case Study 280 Switch Box Redesign Reduces Cost - Case Study 90 Tank Corrosion Investigation - Case Study 71 Team Helps in Magnus Repair - Case Study 55 Teething Troubles… Dental Engineers Given a Helping Hand - Case Study 397 Teletest Focus+ Launched - Case Study 493 Teletest Inspection of Road Crossings on the North Slope - Case Study 210 Teletest Long Range UT Inspection of 12 Inch Heavy Fuel Oil - Case Study 212 Teletest Long Range UT Inspection Trials for Caltex, Indone - Case Study 193 'Teletest' Long-Range UT Inspection of Jetty Lines for Shell - Case Study 192 Teletest Long-Range UT Inspection of Riser Bundles - Case Study 225 Teletest Permamount Guiding the Wave of Innovation - Case Study 565 Teletest Survey of Pipework at ST Services' Eastham Tank Farm - Case Study 222 Teletest® in of a 24'' Slurry Line - Case Study 432 Teletest® Inspection of Road Crossings on the North Slope - Case Study 430 Teletest® Long Range UT Inspection of Jetty Lines for Shell - 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Case Study 338 WallJAM: Beat the Best! - Case Study 622 Warming to Friction Stir Welding - Case Study 451 Weldability of New Pipeline Steel - Case Study 23 Weldasearch for World-Wide Information - Case Study 75 Welded Afterthoughts…..Prompt A Closer Look - Case Study 375 Welding Improvements for the Maritime Industry - Case Study 501 Welding in Space – Who Needs Gravity? - Case Study 92 Welding Trials Permit Reduced Inspection Times - Case Study 44 Welding Up the Tubes - Case Study 260 Welds Before and After Underline Value of Butt Fusion Course - Case Study 348 Wet or Dry…Teletest Exceeds Expectations - Case Study 409 Winch Shaft Failures Diagnosed - Case Study 98 WIP Reduced by 35% in Manufacturing of Filter Units - Case Study 435 Wire/Ribbon Tape Automated Bonding - Case Study 19
 
Published on 26 October 2012

Over 376 friction stir welded (FSW) vehicles have been ordered from Bombardier for the latest Victoria Line upgrade.

The process is being used to join stiff longitudinal extrusions which constitute the carbody's sidewalls. The welding is sub-contracted to Swedish supplier Sapa Profiler, who hold a TWI friction stir welding licence.

FSW is likely to be used on future contracts for over 2200 more new trains in the next decade. This work stems from the successful introduction, some time ago, of friction stir welding on the lower bodyside panels of mainline trains. The technological and commercial advantages of the process were studied and found favourable by Bombardier and London Underground.

Bombardier first showed interest in friction stir welding 11 years ago and Bombardier became a member of the first TWI Group Sponsored Project and has subscribed to several similar projects since then. After a three year process review by Bombardier the manufacturer introduced friction stir welding onto its Electrostar range of vehicles for the UK market.

It is now pursuing its research into friction stir welding through both internal and European projects which are geared towards improving the crash-worthiness of today's rail vehicles throughout Europe.

For more information about Friction Stir Welding, please contact us.

For more information please email:


contactus@twi.co.uk