TWI

With regard to the problem of parameter development for friction stir welding (FSW) of workpieces with 3D joints, a self-tuning algorithm is presented based on the tool-workpiece thermocouple (TWT) method for temperature measurement to facilitate the automatic development of sets of plunge and welding parameters. Welding experiments were conducted on T6-hardened 6000-series aluminium alloys at a travel speed of 10 mm/s using a set-up incorporating an ESAB Rosio FSW robot. An algorithm was developed for the plunging operation, only requiring the material hardness, tool dimensions and welding temperature, and after completion of the plunging operation, the TWT measured temperature was used as input for the multi-output temperature controller in which both rotational speed and axial force could be modified. The methodology was extended to soft 5000-series and artificially hardened 7000-series aluminium alloys.

10th International Symposium, 20-22 May 2014, Session 7A: Inspection, Paper 02