Abstract
The goal of this work is to develop a method for detecting the creation of discontinuities during friction stir welding. This in situ weld monitoring method could significantly reduce the need for post-process inspection. A process force model and a discontinuity force model were created based on the state-of-the-art understanding of flow around an friction stir welding (FSW) tool. These models are used to predict the FSW forces and size of discontinuities formed in the weld. Friction stir welds with discontinuities and welds without discontinuities were created, and the differences in force dynamics were observed. In this paper, discontinuities were generated by reducing the tool rotation frequency and increasing the tool traverse speed in order to create “cold” welds. Experimental force data for welds with discontinuities and welds without discontinuities compared favorably with the predicted forces. The model currently overpredicts the discontinuity size.
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Shrivastava, A., Pfefferkorn, F.E., Duffie, N.A. et al. Physics-based process model approach for detecting discontinuity during friction stir welding. Int J Adv Manuf Technol 79, 605–614 (2015). https://doi.org/10.1007/s00170-015-6868-x
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DOI: https://doi.org/10.1007/s00170-015-6868-x