Development and qualification of a production capable FSW process for 25 mm deep robotic friction stir welds
- Smith C.B. and
- Hinrichs J.F.
- Smith C.B. and
- Hinrichs J.F.
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A production-capable friction stir welding (FSW) process was developed for butt welds (penetration 25.4 mm) in 6061-T6 aluminium alloys, designed specifically for robotic welding of large box assemblies requiring many multi-dimensional weld paths, and characterised with regard to process stability. A baseline process was established for multi-dimensional welding, an FSW tool designed and initial process parameters estimated. Mechanical properties of welds were characterised by tensile and side-bend tests. A design of experiments methodology was employed to achieve baseline process stability by varying rotation speed, travel speed and welding force. Sensitivity to production variables was taken into account and a repair welding procedure was developed. FSW tool life issues are discussed.
6th International Symposium, 10-13 Oct 2006, Session 5A: Process I, Paper 04
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