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Controlled force monitored plug-in tests were undertaken to investigate the influence of rotational speed and to analyse flow regimes during friction stir welding (FSW) of different aluminium alloys. Experimental specimens comprised sheets (thickness 3 or 6 mm) of AA 2024-T3, 6082-T6 and 7075-T6 alloys. FSW was performed using spiral or flat shoulder type tools and threaded or three-flute pins. Friction stir plunge test and continuous friction stir bead-on-plate weld experiments were conducted at rotational speeds of 400-3000 rpm. Issues discussed include the morphology of the nugget, process force monitoring and FSW process parameter set-up.

9th International Symposium, 15-17 May 2012, Session 5A: Process I, Paper 04