Physics-based process model approach for detecting discontinuity during friction stir welding
- Shrivastava A. ,
- Zinn M. ,
- Duffie N. ,
- et al
- Shrivastava A. ,
- Zinn M. ,
- Duffie N. ,
- Pfefferkorn F.E. ,
- Ferrier N.J. and
- Smith C.B.
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Process force and discontinuity models were derived to estimate the forces observed in friction stir welding (FSW) in order to develop a method of detecting discontinuities during FSW using physics-based process modelling. FSW welded joints with and without discontinuity were fabricated, force data from the joints were analysed, the process force and discontinuity force models were proposed to predict forces, and a combined FSW dynamic force model was created. Void discontinuities were generated by reducing the tool rotation frequency and increasing the tool traverse speed to create "cold" welds. Welding experiments were conducted on 6061-T6 alloy plates (thickness 6.35 mm) and 5083-H111 sheets (thickness 4.76 mm) at rotational speeds of 900-1300 rpm and feed rates of 150-500 mm/min. Welding forces were measured with a 3-axis force dynamometer and the frequency content of the forces was analysed using fast Fourier transform plots.
10th International Symposium, 20-22 May 2014, Session 4B: Modelling I, Paper 01
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