Design features for bobbin friction stir welding tools: Development of a conceptual model linking the underlying physics to the production process |
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| Affiliation: | 1. Department of Mechanical Engineering, University of Canterbury, Private Bag 4800, Christchurch 8140, New Zealand;2. School of Engineering, University of Tasmania, Private Bag 65, Hobart 7001, Tasmania, Australia;1. Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, 721302, Kharagpur, India;2. Department of Metallurgical and Materials Engineering, Indian Institute of Technology, Kharagpur, 721302, Kharagpur, India;1. Joining and Welding Research Institute, Osaka University, 11-1 Mihogaoka, Ibaraki, Osaka 567-0047, Japan;2. National Engineering Research Center of Light Alloy Net Forming and State Key Laboratory of Metal Matrix Composite, Shanghai Jiao Tong University, 200030 Shanghai, PR China;1. University of Texas of the Permian Basin, Mechanical Engineering, 4901 East University, Odessa, TX 79762, USA;2. The University of Texas at El Paso, Department of Metallurgical and Materials Engineering, 500 West University Avenue, El Paso, TX 79968, USA;3. NASA Johnson Space Center, Materials and Processes Branch, Houston, TX 77058, USA;1. Friction stir welding Laboratory, Department of Mechanical Engineering, Indian Institute of Technology, Kharagpur, 721 302, India;2. Department of Metallurgical and Materials Engineering, Indian Institute of Technology. Kharagpur, 721 302, India |
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| Abstract: | The effects of different pin features and dimensions of scrolled shoulder bobbin friction stir welding were tested for welding marine grade aluminium, Al6082-T6. Welds were created in longitudinal and transverse plate extrusion directions in thin plate aluminium clamped and supported at one side. Measured outcomes included visual inspection, plate distortion, mechanical properties, metallurgical examination, and hardness test. This study shows that tool features cannot be directly transferable from conventional friction stir welding technology without comprising process variables and tool part functionality. Process setting such as clamps, support arrangements, shoulder gap and welding direction create compression, vibration and heat distribution hence influence the weld quality. The best joint was produced by four flats tool pin followed by threaded tool pin with three flats. These findings were used to develop a conceptual theory representing the underlying physics of the friction stir welding process. The effects of pin features, specifically threads and flats, are identified. This model is useful for direct linking welding factors towards the expected consequences. |
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| Keywords: | Frictions stir welding Bobbin Aluminium Tool features Conceptual model |
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