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The results of a programme to establish self reacting friction stir welding for thin gauge (less than 3 mm) aluminium alloy applications are reported divided into the five major phases: tool development; joint evaluation; strength optimisation; prototype welding; and machine performance. Two pin tool designs (diameters 4.8 and 6.8 mm) were selected and joint thickness tests (3.5 mm tapered start-up tab, and thicknesses 2 and 1.8 mm) were conducted on Al 6061-T6 sheets. The relationship between welding parameters and weld strength was evaluated by a design of experiments approach for both Al 6061-T6 sheets and Al-6N01 flat panels. A short prototype extrusion with internal stiffeners was welded to demonstrate the process. The performance (command versus response) of the AdAPT weld head was assessed.

5th International Symposium, 14-16 Sep 2004, Session 1: Process Development, Paper 02