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Evolution of process parameters in friction stir welding of AA6061 aluminum alloy by varying tool eccentricity

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Abstract

The evolution of processing parameters by varying tool eccentricity in AA6061 alloy friction stir welding was examined using a combination of detailed force/torque measurements and thermal history as well as high-speed camera (HSC) observations. Tri-axial forces show larger oscillations during the steady-state phase of welding if the tool eccentricity is increased. However, the tool torque remains similar for up to 0.4 mm eccentricity versus the aligned tool even with varying weld speed. In situ HSC observation indicates that tool eccentricity is reduced during the welding process for larger eccentric setups. Stir zone thermal measurements reveal that the temperature peaks and stabilizes near the solidus temperature of the AA6061 base material.

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Acknowledgments

The authors would like to acknowledge Alexandre Maltais and Guillaume Bonneau for conducting the friction stir welding and high-speed camera experiments in CSFM.

Funding

This work was supported by the National Science and Engineering Research Council of Canada; Ministry of Education, Malaysia; and Universiti Malaysia Pahang.

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Authors and Affiliations

  1. Centre for Advanced Materials Joining, Department of Mechanical and Mechatronics Engineering, University of Waterloo, Waterloo, Ontario, Canada

    L. H. Shah & A. P. Gerlich

  2. Faculty of Mechanical and Automotive Engineering Technology, Universiti Malaysia Pahang, Pekan, Pahang, Malaysia

    L. H. Shah

  3. Département des Sciences appliquées, Université du Québec à Chicoutimi, Chicoutimi, Quebec, Canada

    A. Fleury & L. St-George

  4. Department of Civil and Environmental Engineering, University of Waterloo, Waterloo, Ontario, Canada

    S. Walbridge

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  1. L. H. Shah
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  4. S. Walbridge
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  5. A. P. Gerlich
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Correspondence to L. H. Shah.

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Shah, L.H., Fleury, A., St-George, L. et al. Evolution of process parameters in friction stir welding of AA6061 aluminum alloy by varying tool eccentricity. Int J Adv Manuf Technol 109, 1601–1612 (2020). https://doi.org/10.1007/s00170-020-05754-4

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