Process forces during friction stir welding of aluminium alloys

Abstract

Flow and consolidation of the material under the tool shoulder and subsequent nugget formation are among the least understood aspects of friction stir welding and processing (FSW/P). Welding parameters and tool profile impact the process forces acting on the tool. This work is an observational study of the process forces associated with bead on plate runs on two aluminium alloys, 6061 and F357. Polar plots of the resultant forces acting on the tool spindle are analysed and correlated to the process parameters. The dependence of the nugget's width with various heat indices is evaluated.