Abstract
Welding, a crucial manufacturing process across various industries, involves forming permanent component joints. Friction stir welding (FSW), an efficient technique is employed for this purpose. FSW requires a fixture to securely hold the workpiece during welding, ensuring precise alignment, minimal deformation and effective heat dissipation. This work focuses on designing a fixture tailored for T-joint configuration FSW of aluminum alloys. Initial concept design was refined for optimal performance with material selection (Mild Steel and EN8) based on requirements. Real-time welding conditions were considered for analysis, leading to the choice of EN8 due to reduced deformation. This paper outlines the steps involved in designing, analyzing and manufacturing a T-joint welding fixture, guaranteeing proper alignment, clamping and heat management during welding.
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