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The present study developed analytical techniques for analysis of welds from various thickness and welding tool designs by expressing the variables of interest in terms of unit area of welding tool surface. Previously, a method of expressing the spindle torque on a unit-area basis resulted in a calculation of the average flow stress in the workpiece at the tool/workpiece interface. This approach was extended here to the calculation of average heat flux and average energy density, which express aspects of welding tool geometry, workpiece thickness, travel speed, spindle speed and observed spindle torque. Additionally, the forge force and resultant in-plane lateral forces on the welding tool are analyzed in terms of tool surface area to yield shoulder pressure and lateral probe pressure. These unit-area quantities are analyzed in this ongoing study with reference to machine settings, excess flash production, macro-section characteristics, defect formation and tensile strength in FSW of aluminum alloys.

13th International Symposium, 21-23 May 2024, Session 12: Plenary IV, Paper 01