The paper presents the results of an experimental investigation, done on the friction stir welding (FSW) plunging stage. Previous research works showed that the axial force and torque generated during this stage were characteristic for a static qualification of a FSW machine. Therefore, the investigation objectives are to better understand the relation between the processing parameters and the forces and torque generated. One of the goals is to find a way to reduce the maximum axial force and torque occurring at the end of the plunging stage in order to allow the use of a flexible FSW machine. Thus, the influence of the main plunge processing parameters on the maximum axial force and torque are analysed. In fact, forces and torque responses can be influenced by the processing parameter. At the end, a diagram presenting the maximum axial force and torque according to the processing parameters is presented. It is an interesting way to present the experimental results. This kind of representation can be useful for the processing parameters choice. They can be chosen according to the force and torque responses and consequently to the FSW machine capacities.
Ball-burnishing is presented herein as a mechanical surface treatment for improving mechanical properties after the friction stir welding process. Ball-burnishing provides good surface finish, high compressive residual stresses, and a hardness increase of the surface layer. These characteristics are key for the fatigue life improvement of the component, and for wear resistance due to the higher hardness. This work presents a complete analysis of surface and sub-surface hardness values focusing on the determination of each process parameter influence. Burnishing pressure, radial width, and burnishing direction influence were analyzed. The tested material was 2050 aluminum alloy with two different heat treatments (T3 and T8). The optimum parameters were established, and a complete analysis of the surface hardness was performed. Results show that burnishing is an economical and feasible mechanical treatment for the quality improvement of component surfaces.
During Friction Stir Welding process, FSW, a tool / workpiece mechanical interaction is generated leading to forces and torques applied on the tool. These forces and torques are transmitted to the welding equipment impacting its technical requirements. This paper presents a forces and torques analysis according to the processing parameters on the welding at constant speed stage. The analysis was performed on the whole welding process windows, by varying one process parameter after the other. The goal of this work is to determine if and how the forces and torque could be reduced by working on the processing parameters. So, with lower forces and torque applied on the tool, the use of a standard and flexible welding equipment, allowing the welding of complex geometries, could be enabled.
This paper presents an experimental methodology to determine a Friction Stir Welding (FSW) means of production based on the experimental study of the tool / material mechanical interactions generated during the plunging and welding stages. These two stages have been identified as being characteristic for the qualification of a FSW equipment. This paper presents the experimental results of the parametric study done on the plunging and welding phases. Ranges of forces and torques diagrams were established according to the processing parameters, in order to qualify a means of production and select the process parameters allowing the operation on the available FSW equipment.
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