Towards force measurement based discontinuity detection during friction stir welding
- Shrivastava A. ,
- Zinn M. ,
- Duffie N.A. ,
- et al
- Shrivastava A. ,
- Zinn M. ,
- Duffie N.A. ,
- Pfefferkorn F.E. ,
- Smith C.B. and
- Ferrier N.J.
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Description
An approach to welded joint inspection incorporating in situ characterisation of weld quality was developed to facilitate the detection of discontinuities (e.g. voids and volume defects) during friction stir welding (FSW). FSW experiments were performed on 6061-T6 aluminium alloy plates (thickness 6.35 mm) using a CNC mill under position control in order to fabricate weldments with and without subsurface voids, the former achieved by reducing the tool rotational frequency (600-1000 rpm) and increasing traverse speed (467-1000 mm/min) to create 'colder' welds. Process forces were measured with a 3 axis force dynamometer and void sizes were determined post process using computerised tomography (3D X-ray imaging). Two parameters, based on frequency domain content and time domain average of force signals, were correlated with void size. Criteria for subsurface void detection and size prediction are discussed.
11th International Symposium, 17-19 May 2016, Session 10B: Monitoring-Inspection, Paper 02
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