TWI

A comparative study was undertaken of three different machine types, a modified high payload robot, a CNC milling machine and an ESAB "SuperStir" FSW machine, in terms of their capability for FSW of various aluminium alloys using identical process parameters. The materials studied were sheet or plate specimens (thickness 1-8 mm) of AW 5083-H111 (Al, 4-4.9%Mg), AW 6060-T66 (Al, 0.35-0.6%Mg, 0.3-0.6%Si) and AC 46000 (Al, 8-11%Si, 2-3.5%Cu, 1.2%Zn). Welding was conducted in a butt joint configuration using the same clamping device for all experiments. Welded joints were evaluated by visual inspection, macrostructure observations, hardness measurements, bend tests and tensile tests. Issues discussed include force feedback control, maximum process forces and machine stiffness.

7th International Symposium, 20-22 May 2008, Poster Session, Paper 05