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

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

doi:10.1177/2041297510393629

Cited by 12 publications

(3 citation statements)

References 12 publications

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“…The decay of the torque signal as the tool loses volume presents a potential avenue for control of the wear process. Gibson et al (2011)simulated adaptive torque control for the purpose of wear estimation in FSW of MMCs. The proposed controller estimates the probe radius based on the torque signal and adjusts the controlling variable (plunge depth) to maintain a constant, desired value of torque.…”

Section: Discussionmentioning

confidence: 99%

“…The expression for torque derived from the rotating plug model (equation (2) predicts that the tool geometry has a significant impact on torque. According to this formulation, the t radial deterioration of the probe during joining of MMCs by FSW should correspond to a decrease in the magnitude of the torque experienced by the tool (Gibson et al, 2011). This result raises the question as to whether in situ estimates of wear can be made based only on the torque signal.…”

Section: Theory: the Rotating Plug Model And Torquementioning

confidence: 99%

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Evaluation of torque as a means of in-process sensing of tool wear in friction stir welding of metal matrix composites

Prater

Gibson

Cox

et al. 2015

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Purpose The purpose of this paper is to evaluate the tool experiences using torque during welding as a means of in-process sensing for tool wear. Metal matrix composites (MMCs) are materials with immense potential for aerospace structural applications. The major barrier to implementation of these materials is manufacturability, specifically joining MMCs to themselves or other materials using fusion welding. Friction stir welding (FSW) is an excellent candidate process for joining MMCs, as it occurs below the melting point of the material, thus precluding the formation of degradative intermetallics’ phases present in fusion welded joints. The limiting factor for use of FSW in this application is wear of the tool. The abrasive particles which give MMCs their enhanced properties progressively erode the tool features that facilitate vertical mixing and consolidation of material during welding, resulting in joints with porosity. While wear can be mitigated by careful selection of process parameters and/or the use of harder tool materials, these approaches have significant complexities and limitations. Design/methodology/approach This study evaluates using the torque the tool experiences during welding as a means of in-process sensing for tool wear. Process signals were collected during linear FSW of Al 359/SiC/20p and correlated with wear of the tool probe. The results of these experiments demonstrate that there is a correlation between torque and wear, and the torque process signal can potentially be exploited to monitor and control tool wear during welding. Findings Radial deterioration of the probe during joining of MMCs by FSW corresponds to a decrease in the torque experienced by the tool. Experimentally observed relationship between torque and wear opens the door to the development of in-process sensing, as the decay in the torque signal can be correlated to the amount of volume lost by the probe. The decay function for tool wear in FSW of a particular MMC can be determined experimentally using the methodology presented here. The decay of the torque signal as the tool loses volume presents a potential method for control of the wear process. Originality/value This work has near-term commercial applications, as a means of monitoring and controlling wear in process could serve to grow commercial use of MMCs and expand the design space for these materials beyond net or near-net-shape parts.

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Section: Discussionmentioning

confidence: 99%

Section: Theory: the Rotating Plug Model And Torquementioning

confidence: 99%

Evaluation of torque as a means of in-process sensing of tool wear in friction stir welding of metal matrix composites

Prater

Gibson

Cox

et al. 2015

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“…Experimental results verified the ability of the developed adaptive control system to continuously adjust the parameters in real time despite the variation in the gap and mismatch. Adaptive control has also been studied for torque control in FSW [263]. Welding high melting point alloys and MMC experiences an accelerated rate of tool wear.…”

Section: Dynamicmentioning

confidence: 99%

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Zhang

Yang

Wei

et al. 2020

Journal of Manufacturing Science and Engineering

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Welding is a major manufacturing process that joins two or more pieces of materials together through heating/mixing them followed by cooling/solidification. The goal of welding manufacturing is to join materials together to meet service requirements at lowest costs. Advanced welding manufacturing is to use scientific methods to realize this goal. This paper views advanced welding manufacturing as a three step approach: (1) pre-design that selects process and joint design based on available processes (properties, capabilities, and costs); (2) design that uses models to predict the result from a given set of welding parameters and minimizes a cost function for optimizing the welding parameters; (3) real-time sensing and control that overcome the deviations of welding conditions from their nominal ones used in optimizing the welding parameters by adjusting the welding parameters based on such real-time sensing and feedback control. The paper analyzes how these three steps depend on process properties/capabilities, process innovations, predictive models, numerical models for fluid dynamics, numerical models for structures, real-time sensing, and dynamic control. The paper also identifies the challenges in obtaining ideal solutions and reviews/analyzes the existing efforts toward better solutions. Special attention and analysis have been given to (1) gas tungsten arc welding (GTAW) and gas metal arc welding (GMAW) as benchmark processes for penetration and materials filling; (2) keyhole plasma arc welding (PAW), keyhole-tungsten inert gas (K-TIG), and keyhole laser welding as improved/capable penetrative processes; (3) friction stir welding (FSW) ......

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Wear-Induced Changes in FSW Tool Pin Profile: Effect of Process Parameters

Sahlot

Jha

Dey

et al. 2018

Metall Mater Trans A

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

Cited by 12 publications

References 12 publications

Evaluation of torque as a means of in-process sensing of tool wear in friction stir welding of metal matrix composites

Evaluation of torque as a means of in-process sensing of tool wear in friction stir welding of metal matrix composites

Advanced Welding Manufacturing: A Brief Analysis and Review of Challenges and Solutions

Wear-Induced Changes in FSW Tool Pin Profile: Effect of Process Parameters

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