Forge force reduction via tool design variation
- Cole E.G. ,
- Ferrier N.J. ,
- Zinn M.R. ,
- et al
- Cole E.G. ,
- Ferrier N.J. ,
- Zinn M.R. ,
- Duffie N.A. and
- Pfefferkorn F.E.
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Friction stir welding (FSW) experiments were undertaken on sheet specimens (thickness 5 mm) of 5454-H111 aluminium alloys and the relationships between process forces, spindle power and tool geometry were investigated. Twelve FSW tools with specified design features (varying in number of flats (0-4), flat depth (max.0.625 mm), thread lead (0.6-1 mm), thread depth (0.0525-0.875 mm) and shoulder diameter (12-18 mm)) were machined from H13 tool steel. Butt welds were fabricated using a commercial 3-axis CNC milling machine under position control. Welding forces and spindle torque were measured with a 3-axis force dynamometer and a current probe, respectively. Weldments were characterised by microstructure observations and tensile tests. The effect of tool geometry on joint strength and weld nugget quality is discussed.
9th International Symposium, 15-17 May 2012, Poster Session, Paper 02
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