Friction stir welding (FSW) is a process originally developed for joining light materials, such as aluminum and magnesium, as an answer to their poor weldability by conventional fusion processes. In Colombia, the technique has been studied but its industrial implementation is uncommon, due to the high cost of specialized machinery and the unfamiliarity with the technique of local industries. This article presents an implementation case study of FSW on a 6082-aluminum alloy train component from Metro de Medellín (MdM), aiming to establish the component design changes required to accommodate the FSW process, and conventional machines available in the local area which may be available for welding. Additionally, a simple comparison was made between the cost of this approach versus the manufacturing strategy currently used for the selected component. Initially, welding forces were measured when performing the seam on the selected component using an FSW machine. This data was then used to downselect the local milling machines with these capabilities. A simple but specific tool was designed for the geometry of one of the component features. Finally, a prototype was fabricated, and weld samples were obtained, polished, etched, and examined using a microhardness machine and an optical microscope. Results show a good opportunity for the execution of simple components with uniform geometries, which can be carried out using locally available machinery because they do not surpass their maximum loading capacity, the welds do not present visible discontinuities, and an average hardness of 69.5 HV and mechanical efficiency of 95% can be achieved. Additionally, the manufacturing process is around 30% cheaper compared to traditional methods, making the application viable, economically speaking.
Friction Stir Welding (FSW) is a solid-state welding process that has multiple advantages over fusion welding. The design of tools for the FSW process is a factor of interest, considering its fundamental role in obtaining sound welds. There are some commercially available alternatives for FSW tools, but unlike conventional fusion welding consumables, their use is limited to very specific conditions. In this work, equations to act as guidelines in the design process for FSW tools are proposed for the 2XXX, 5XXX, 6XXX, and 7XXX aluminum series and any given thickness to determine: pin length, pin diameter, and shoulder diameter. Over 80 sources and 200 tests were used and detailed to generate these expressions. As a verification approach, successful welds by authors outside the scope of the original review and the tools used were evaluated under this development and used as case studies or verification for the guidelines. Variations between designs made using the guidelines and those reported by other researchers remain under 21%.
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