Abstract
Reports in the literature indicate that temperature control in Friction Stir Welding (FSW) enables better weld properties and easier weld process development. However, although methods of temperature control have existed for almost two decades, industry adoption remains limited. This work examines single-loop Proportional-Integral-Derivative (PID) control on spindle speed as a comparatively simple and cost-effective method of adding temperature control to existing FSW machines. Implementation of PID-based temperature control compared to uncontrolled FSW in AA6111 at linear weld speeds of 1–2 m per minute showed improved mechanical properties and greater consistency in properties along the length of the weld under temperature control. Additionally, results indicate that a minimum spindle rpm may exist, above which tensile specimens do not fracture within the weld centerline, regardless of temperature. This work demonstrates that a straightforward, PID-based implementation of temperature control at high weld rates can produce high quality welds.
Highlights
The side that benefits from the combination of rotational and translational components of velocity is known as the advancing side, while the other side of the weld is known as the retreating side
The primary methods of temperature control that have been suggested over the past decade have previously been reviewed in [14], where single-loop PID control was determined to be the simplest to implement, when controlling the spindle speed based on the tool temperature
Per ASM handbook volume 2B, the Ultimate Tensile Strength (UTS) of AA6111T4 generally ranges from 250–285 MPa, while AA6111-T6 has a UTS of 340 MPa [14]
Summary
Solid-state welding, or the joining of materials below their bulk melting temperatures, has been evaluated in various forms for millennia. The heat generated of the deformation material is specific the geometry of the the process the weld, from of the to material is specific to tool, the geometry of parameters the tool, theofprocess paand the characteristic temperature dependent properties of the material being joined. Energy and compressive pressure on the weld nugget that generates heat through friction Initial implementations of FSW relied on skilled research teams to develop a specific and deformation. Welding parameter for a fixed tool and set of boundary conditions to achieve a desired Initial implementations of FSW relied on skilled research teams to develop a specific output. Significant efforts have been implementovercome axial force furhowever, more extensive control is needed to bemade able totocompletely thecontrol, challenges ther simplifying the complex and coupled interactions between the tool and the of developing process parameters for FSW. Workpiece; more extensive control is needed to be able to completely overcome the challenges of developing process parameters for FSW
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