Abstract
Friction Stir Welding (FSW) is a solid-state welding process that has multiple advantages over fusion welding. The design of tools for the FSW process is a factor of interest, considering its fundamental role in obtaining sound welds. There are some commercially available alternatives for FSW tools, but unlike conventional fusion welding consumables, their use is limited to very specific conditions. In this work, equations to act as guidelines in the design process for FSW tools are proposed for the 2XXX, 5XXX, 6XXX, and 7XXX aluminum series and any given thickness to determine: pin length, pin diameter, and shoulder diameter. Over 80 sources and 200 tests were used and detailed to generate these expressions. As a verification approach, successful welds by authors outside the scope of the original review and the tools used were evaluated under this development and used as case studies or verification for the guidelines. Variations between designs made using the guidelines and those reported by other researchers remain under 21%.
Highlights
Friction Stir Welding (FSW) is a solid-state welding process patented in 1991 byThe Welding Institute (TWI)
FSW applications increase due to the excellent results obtained with these alloys [3]
It is important to clarify that the expressions proposed only account for the basic tool dimensions; other aspects such as threading, pin shape, shoulder features, among others, were defined using trends identified in the literature review
Summary
This method is performed by utilizing a non-consumable cylindrical tool that rotates and advances in the material to be welded; this movement produces heat through friction and mixes the softened material to produce the weld [1]. FSW applications increase due to the excellent results obtained with these alloys [3]. They are used in the railway [4], aerospace [5,6], automotive [7,8], and shipbuilding industries [9].
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