TWI

An investigation was undertaken to examine the interactions, required process adjustments and resultant joint properties associated with conventional and robotic stationary shoulder friction stir welding (SSFSW) for scaled tool geometries. In order to study the influence of tool geometry on the FSW process, experiments were carried out on AW 5754-H12 and AW 6082-T6 aluminium alloy sheets (thickness 5 mm) using conventional tool aspect ratios. Welded joints were characterised by visual inspection, metallography and tensile testing. Conventional FSW was conducted at a travel speed of 1000 mm/min and rotational speed of 2000-5500 rpm. SSFSW was used to fabricate bead on plate welds in AW 6082-T6 at rotational speeds of 3500 or 5000 rpm and in AW 5754-H12 at travel speeds of 1000-1400 mm/min. Issues discussed include defect formation at high rotational speed in conventional FSW and weld cross sections, nugget width and penetration depth in SSFSW.

11th International Symposium, 17-19 May 2016, Session 3A: Robotic and Non Linear, Paper 03