Force feedback-based quality monitoring of the friction stir welding process utilizing an analytic algorithm
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RESEARCH PAPER
Force feedback-based quality monitoring of the friction stir welding process utilizing an analytic algorithm P. Rabe 1
&
A. Schiebahn 1
&
U. Reisgen 1
Received: 2 September 2020 / Accepted: 28 November 2020 # The Author(s) 2020
Abstract The friction stir welding (FSW) process is known as a solid-state welding process, comparatively stable against external influences. Therefore, the process is commonly used with fixed welding parameters, utilizing axial force control or position control strategies. External and internal process disturbances introduced by workpiece, gap tolerance, tool wear, or machine/tool inadequacies are rarely monitored, and conclusions about the weld seam quality, based on the recorded process data, are not drawn. This paper describes an advancement, improving on research into the correlation of process force feedback events or gradual force changes and the resulting weld seam characteristics. Analyzing the correlation between examined weld sections and high-resolution rate force data, a quality monitoring system based on an analytic algorithm is described. The monitoring system is able to accurately distinguish sound welds from such with internal (void) and external (flash) defects. Keywords Friction stir welding FSW . Quality monitoring . Force feedback
1 Introduction The friction stir welding process, which was introduced and patented in 1991 by TWI, enables the reproducible joining of mainly nonferrous metals [1]. The joint formation based on intermixing of plasticized metals allows for firmly bonded welding of non-fusion weldable alloys, while at the same time increasing joint quality compared to fusion welding processes by eliminating the formation of metallurgical pores and minimizing distortion [2]. From the beginning of its industrial use until today, FSW has been used in applications requiring the joining of high performance alloys and minimization of distortion. Starting in 1993, NASA used FSW for the joining of lithiumcontaining Al-alloys for its space shuttle fuel tanks. FSW was the only way to reliably join this high strength-toweight ratio alloy and to achieve weld seam properties Recommended for publication by Commission III - Resistance Welding, Solid State Welding, and Allied Joining Process * P. Rabe [email protected] 1
ISF – Welding and Joining Institute, RWTH Aachen University, Pontstr. 49, 52062 Aachen, Germany
comparable to the mechanical properties of the base material to exhaust the alloy’s potential [3]. FSW has spread further into industrial use, being employed to maximize material properties and save weight in car bodies and panels [4], as well as trains and ships [5] and entertainment electronics [6]. After the end of the patent protection in 2015, the following elimination of licensing costs [7] and the ever increasing trend towards light weight construction, the interest for further industrial applications spiked. While being regarded as a stable, reliable process, suitable monitoring, and tracing methods are in increasing demand. Com
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