Development of a welding platform and tool for the study of weld and process parameters, during continuous friction stir welding of AA6082-T6 sheets

Abstract

Bobbin tool friction stir welding is a relatively novel technology whose application, despite its benefits, is still limited due to unfamiliarity presented by less published literature. Advantages associated with the bobbin-tool technique lie imbedded in the resultant double-sided processed zone, of somewhat rectangular cross section, along the joint line. Currently, the joint integrity benefits are overshadowed by high setup costs associated with slightly more complex tool and platform designs of bobbin-tool friction stir welding. To largely exploit and optimise the technique, there is need for an in-depth understanding of interaction between welding parameters and response variables. This comprehension could assist with process optimisation, reproducibility, automation and possibly process economic feasibility. This paper proposes design considerations with regards to development of a continuous solid-state welding platform and tool, for instrumentation of process output variables. As an instance, upon tool and platform development, calibration and verification, data acquisition of weld forces developed during bobbin-tool friction stir welding, as a function of process time, can then be implemented to enable analysis. Feasibility of the proposed methodology is then left for evaluation in future work. Thus, analysis of weld forces can be facilitated by the design and development of an instrumented fixture and a bobbin friction stir welding tool, in joining AA6082-T6 aluminium plates.