TWI

A review is presented of the state-of-the-art of industrial friction stir welding (FSW) mass production, current trends, challenges and market demands as well as the potential of high speed complex contour welding on multi-axis FSW machinery with respect to process parameters, material properties, machinery requirements and control algorithms and methods. Complex 3D contours as a design strategy to optimise efficiency are outlined and implementation challenges are summarised. Requirements for high speed welding of 3D contours are described such as force control, machine rigidity, machine kinematics, temperature control and process and clamping forces. Other issues discussed include a methodology for sustaining high quality welds, the handling of distortions and residual stresses by thermal management and process parameter optimisation.

12th International Symposium, 26-28 Jun 2018, Session 8A: Robotic & Non Linear, Paper 01