TWI

An overview is presented of the benefits and limitations of stationary shoulder friction stir welding (SSFSW) compared with conventional FSW and other joining technologies; the challenges faced when applying FSW on a serial kinematics robot in relation to process forces and torque; the ability of laser seam tracking to improve robot accuracy; and the use of case studies to demonstrate the implementation of robotic SSFSW for different geometries. Issues discussed include shaped corner and corner FSW; the effects of tool forces and subsequent tool deviations in robotic FSW; tool position correction using laser seam tracking; the FlexiFab robotic FSW system; linear SSFSW of AA 7075-T6 aluminium alloy sheets (thickness 3 mm); part tolerance and fit up; 3D SSFSW of AA 6082-T6; path programming; linear corner FSW of AA 2024-T3; and sensitivity to gaps, plate tolerances, plunge parameters and tool orientation variation.

11th International Symposium, 17-19 May 2016, Session 3A: Robotic and Non Linear, Paper 02