A Phenomenological Model for Tool Wear in Friction Stir Welding of Metal Matrix Composites

Prater, Tracie; Strauss, Alvin M.; Cook, Gerald; Gibson, Brian T.; Cox, Chase

doi:10.1007/s11661-013-1701-3

Cited by 23 publications

(26 citation statements)

References 6 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…Another case is when high strength tool materials are used in the welding of high melting point or highly abrasive alloys. Tool materials that are wear resistant are often more brittle and prone to facture, which can dictate that more conservative parameters be used to protect the tool [52]. In cases such as this, process variants might be used to recapture some of the weld strength lost.…”

Section: Discussionmentioning

confidence: 99%

Friction stir lap joining of 2198 aluminum–lithium alloy with weaving and pulsing variants

Gibson

Ballun

Cook

et al. 2015

Journal of Manufacturing Processes

View full text Add to dashboard Cite

Section: Discussionmentioning

confidence: 99%

Friction stir lap joining of 2198 aluminum–lithium alloy with weaving and pulsing variants

Gibson

Ballun

Cook

et al. 2015

Journal of Manufacturing Processes

View full text Add to dashboard Cite

“…Experiments have shown that assuming a linear relationship between tool wear and distance traversed is valid, given particular rotation speeds Fig. 7 Rotating plug model and traverse rates [8]. The linear decrease in probe radius began at 20 s and continued throughout the simulation.…”

Section: Simulating Uniform Probe Wearmentioning

confidence: 99%

“…In a study by Prater et al [8], a formula was developed through statistical analysis that predicts the amount of wear on a steel trivex tool while welding MMC (Al 359/SiC/20P). The percentage tool wear is given by [8] W ¼ 0:584ðl Þ À 1:038ðvÞ þ 0:009ðwÞ À 6:028…”

Section: Tool Wearmentioning

confidence: 99%

Adaptive torque control of friction stir welding for the purpose of estimating tool wear

Gibson

Cook

Prater

et al. 2011

Proceedings of the Institution of Mechanical Engineers, Part B:

View full text Add to dashboard Cite

In this paper, an adaptive torque controller for friction stir welding (FSW) that can estimate parameters such as probe radius which may be changing throughout the welding process is presented. Implementing an adaptive controller with this capability would be of interest to industry sectors in which FSW is performed on high melting point alloys or metal matrix composites (MMC). Welding these materials has shown a greatly accelerated rate of tool wear. Simulations were conducted to examine how extreme tool wear would affect controller performance and how accurately the controller could estimate the probe radius. A simplified wear model consisting of a linear decrease in probe radius was used to verify controller performance. Next, a wear model consistent with wear patterns seen in the welding of highly abrasive materials was developed. Results indicate that torque is controlled effectively while a change in system dynamics is experienced, as would be expected with adaptive control, but also that the tool profile is accurately estimated after an initial identification period.

show abstract

“…correspond to divergent results. This may be a consequence of the asymmetry of effects: in the study by Prater et al, 8 the process variables do not carry equal weight (i.e. a change in one variable may have a greater impact on wear than a proportional change in another variable).…”

Section: The Derivation Of the Dimensionless Numbermentioning

confidence: 99%

“…There are comparatively fewer studies of the tool wear which accompanies FSW of metal composites. Foremost of these is the progression of tool wear in FSW of aluminum MMCs reinforced with aluminum oxide particles (volume fraction 20%) documented by Prado et al 6,7 The study by Prater et al 8 builds upon this study, quantifying the contribution of three major process variables (rotation speed, traverse speed, and length of weld) on the amount of wear as well as developing a predictive process model of wear based on empirical data. Wear in these experiments was measured using an optical technique: pre-and post-weld images of the tool probe were compared in computer imaging software to quantitatively assess the degree of volume loss.…”

Section: Introductionmentioning

confidence: 98%

Dimensional analysis and a potential classification algorithm for prediction of wear in friction stir welding of metal matrix composites

Prater

Cox

Gibson

et al. 2012

Proceedings of the Institution of Mechanical Engineers, Part C:

View full text Add to dashboard Cite

The objective of this study is to develop a dimensionless parameter which can be used to estimate the amount of volumetric wear, a friction stir welding tool will experience in joining a metal matrix composite. Metal matrix composites are strong, lightweight materials consisting of a metal matrix (often an aluminum alloy) reinforced with ceramic particles or fibers. This study derives a dimensionless number based on three major process variables in friction stir welding: rotation speed, traverse speed, and length of weld. This number is correlated with wear data collected from experiments in which a steel friction stir welding tool was used to join Al 359/SiC/20p. The use of the dimensionless number as a classifier for tool condition is also evaluated.

show abstract

A Phenomenological Model for Tool Wear in Friction Stir Welding of Metal Matrix Composites

Cited by 23 publications

References 6 publications

Friction stir lap joining of 2198 aluminum–lithium alloy with weaving and pulsing variants

Friction stir lap joining of 2198 aluminum–lithium alloy with weaving and pulsing variants

Adaptive torque control of friction stir welding for the purpose of estimating tool wear

Dimensional analysis and a potential classification algorithm for prediction of wear in friction stir welding of metal matrix composites

Contact Info

Product

Resources

About