Engineering Commons^™

Quantification Of The Effect Of Tool Geometric Features On Aspects Of Friction Stir Welding, Md. Reza-E-Rabby

Theses and Dissertations

In the friction stir welding (FSW) process, tool stirring and synchronized movement of the weld materials along a pre-existing seam line causes thermal gradients and severe plastic deformation resulting in the bonding of the adjacent materials. For a given set of welding parameters, tool pin geometries (dimensions, shape) and vertical/helical features that dictate the material motion also have significant effects on process response variables during FSW. Among the primary process controlling parameters in FSW, tool pin geometry and feature vary multifariously in terms of shape, dimensions, feature insertion technique depending on the weld material and application of joint. The current …

Design Of Experiments Analysis Of Non-Standard Inputs For The Optimization Of Friction Stir Welding, Ryan Widejko

Theses and Dissertations

The purpose of this study was to use non-standard Design of Experiments (DoE) inputs in Friction Stir Welding (FSW) to deduce relationships between various weld input and response variables. Typically, inputs for FSW DoE are tool rotational speed, welding speed and forge force. In this study, three different input factors were investigated: travel speed, thermal boundary conditions (TBC), and advance per revolution (APR). The experimental design included a full factorial with each factor at two levels plus two centerpoint runs. Response variables included weld temperature, microstructure, hardness, power, weld energy, and in plane forces.

An investigation of the effect of …