TWI

The detection principles of 3D forces during bobbin tool friction stir welding (BT-FSW) were considered and the filtered data of axial force, tool torque and horizontal force were analysed to develop models to describe the relationships between torque and welding process parameters. 3D forces were determined using various force sensors and a dynamic torque sensor. BT-FSW experiments were conducted on AA 6061 alloys (Al, 1%Mg, 0.6%Si) at rotational speeds of 600-1100 rpm and welding speeds of 20-120 mm/min using a modified milling machine and tools made from HM1 tool steel. Differences between the horizontal force direction and the welding direction and an increasing alloy effect on material flow resistance at high rotational speeds are discussed.

10th International Symposium, 20-22 May 2014, Session 9B: Modelling II, Paper 05