TWI

An investigation is presented into the influence of tool flats, tool runout magnitude and relative tool runout orientation on the high speed forces acting transversely and longitudinally on the friction stir welding tool. Partial penetration bead-on-plate welds were fabricated in AA 2219-T87 aluminium alloy plates (thickness 6.4 mm) using an MP-159 cylindrical tool or a WC triangular tool and a flat-bottomed cylindrical pin (with or without three flats). Welding was performed with an MTI RM-1 machine at a spindle rotation speed of 400 rpm, travel speed of 90 mm/min and tilt of 2.5 degrees. A National Instruments PXI-6123 data acquisition board was used to obtain weld force and tool angular position data at high capture rates. The runout of the weld tool shoulder outer diameter was measured with a lever-arm type dial indicator. The relative phase shift between overall tool runout location and the direction of maximum XY-planar force is discussed.

9th International Symposium, 15-17 May 2012, Session 4B: Modelling I, Paper 04