TWI

An investigation was undertaken to examine the use of an industrial serial robot incorporating dual loop force/position control to reduce the investment cost and increase process flexibility in friction stir welding (FSW) by compensating the lateral pin deviation. Industrial case studies involving the testing of 1D, 2D and 3D aluminium alloy weldments on real parts were conducted. A second position control loop with secondary encoders was employed and combined with a force control loop along the forging axis. 1D, 2D and 3D welds were fabricated on AA 5754-H22 sheets (thickness 3 mm), AA 7175-T7351 and AA 5182-H19 sheets (thickness 0.85 mm), respectively. Welded joints were characterised by metallographic cross sectional microstructure observations and bend testing. Lateral tool deviation was measured with a laser distance sensor.

11th International Symposium, 17-19 May 2016, Session 3A: Robotic and Non Linear, Paper 04