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Real-Time Measurement of Friction Stir Tool Motion During Defect Interaction in Aluminum 6061-T6

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Friction Stir Welding and Processing XI

Part of the book series: The Minerals, Metals & Materials Series ((MMMS))

Abstract

The objective of this research is to develop a fundamental understanding of the interaction between features on the friction stir tool probe and volumetric sub-surface defects formed during welding. This will guide the development of real-time defect monitoring methods that will promote process adoption in high volume and high-reliability applications. A single-head laser Doppler vibrometer system was used to produce a non-contact measurement of the eccentric motion of a friction stir tool during welding. When features on the tool probe interacted with voided volumes, the tool was momentarily deflected into the voided volume. The distortion signals in the tool position, measured with the laser vibrometer, are correlated with distortions in measured process forces and defect size. The results add understanding to the changes in forces signals that hold potential for defect monitoring and suggest that monitoring may be possible through a motion-based measurement (accelerometer) from the tool side.

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Acknowledgements

The authors gratefully acknowledge financial support of this work by the Department of Mechanical Engineering at the University of Wisconsin-Madison and the U.S. National Science Foundation through grant CMMI-1826104. The authors would also like to acknowledge Prof. Melih Eriten and Lijie Liu for loaning and guidance on the use of the laser vibrometer system, which was enabled through the National Science Foundation MRI Grant CMMI 1725413.

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Authors and Affiliations

  1. Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI, USA

    Daniel J. Franke, Michael R. Zinn, Shiva Rudraraju & Frank E. Pfefferkorn

Authors
  1. Daniel J. Franke
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  2. Michael R. Zinn
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  3. Shiva Rudraraju
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  4. Frank E. Pfefferkorn
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Corresponding author

Correspondence to Frank E. Pfefferkorn .

Editor information

Editors and Affiliations

  1. Brigham Young University, Provo, UT, USA

    Yuri Hovanski

  2. Tohoku University, Sendai, Japan

    Yutaka Sato

  3. Pacific Northwest National Laboratory, Richland, WA, USA

    Piyush Upadhyay

  4. Peter the Great St. Petersburg Polytechnic University, Saint Petersburg, Russia

    Anton A. Naumov

  5. The University of Alabama, Tuscaloosa, AL, USA

    Nilesh Kumar

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© 2021 The Minerals, Metals & Materials Society

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Franke, D.J., Zinn, M.R., Rudraraju, S., Pfefferkorn, F.E. (2021). Real-Time Measurement of Friction Stir Tool Motion During Defect Interaction in Aluminum 6061-T6. In: Hovanski, Y., Sato, Y., Upadhyay, P., Naumov, A.A., Kumar, N. (eds) Friction Stir Welding and Processing XI . The Minerals, Metals & Materials Series. Springer, Cham. https://doi.org/10.1007/978-3-030-65265-4_7

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