Development of friction stir welding technologies for in-space manufacturing

Longhurst, William R.; Cox, Chase; Gibson, Brian T.; Cook, Gerald; Strauss, Alvin M.; Wilbur, Isaac C.; Osborne, Brandon E.

doi:10.1007/s00170-016-9362-1

Cited by 29 publications

(15 citation statements)

References 8 publications

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“…It was reported that the BFSW save about 20 to 25% of power consumption than the CFSW and GMAW welding [6]. Longhurst et al [7] found that the welding force of BFSW process is relatively lower than the CFSW. Esmaily et al [8] reported that the BFSW produced high heat input than the CFSW due to the presence of the lower shoulder.…”

Section: Introductionmentioning

confidence: 99%

“…Esmaily et al [8] reported that the BFSW produced high heat input than the CFSW due to the presence of the lower shoulder. Various studies in utilising process signals have been adopted by many researchers using CFSW, which explained in [9] but in the case of BFSW, only a few studies [6][7][8] were recorded. Therefore, this study was conducted to identify the variation that occurred during welds formation in BFSW process by recording the current, force and temperature signals.…”

Section: Introductionmentioning

confidence: 99%

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Evaluation of Current, Force and Temperature Signals on Welding Formation of Bobbin Friction Stir Welded AA1100

Sued

Nasir

Abidin

2021

IJAME

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Understanding process response through measuring process signal provides on-site information in the area of process monitoring, which saves time and costs. The type of signals depends upon the type of process, equipment and machines used through sensors attached on the equipment used in the process. This is an important method for detecting changes in the process that reflect the condition or quality of the weld. The benefits of this method, however, has not been well performed for Bobbin friction welding. This process is different from conventional friction welding due to the different process set-up in term of tooling and parameters, hence the need to evaluate the signal response. Consequently, signal measuring for welding plate AA1100 was carried out. Tool rotation ranged from 750 rpm to 950 rpm with a fixed travel rate of 130 mm/min on a CNC milling machine and a fixed spacing tool. During the joining process, welding temperature, current consumption and welding force were measured. The resulting data were then plotted on the X-Y axis chart and mapped using the welded plate identifying the welding phase. From the welding force and current measurement, it is found that high force and current is detected at the tool entry phase and exit. As the tool moves towards the end of the plate, the temperature increased. The highest current and strength are measured when the spindle speed is at the lowest, while the highest temperature is at the fastest spindle speed. In weld phase, a current of approximately 6.5 A, a force of 1 kN and a temperature of 320º was measured. A maximum weld strength of 102.860 MPa achieved using a speed of 950 rpm. A slow spindle speed at the entrance area and a high spindle speed at the weld phase are needed to optimise the process.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Evaluation of Current, Force and Temperature Signals on Welding Formation of Bobbin Friction Stir Welded AA1100

Sued

Nasir

Abidin

2021

IJAME

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“…Conventional fusion-based welding techniques are the preferred processes but suffer from limitations including undesirable joint microstructures, high distortion, high skill required, and are sometimes simply unsuitable for certain applications. 1 The increasing demand of non-fusion joining techniques is moving towards the recent and promising solid-state joining technique known as friction stir welding (FSW). This is especially desired for difficult to join material combinations (such as several difficult to weld Al-alloys, 1 dissimilar alloys, 2 and varieties of steels, titanium and nickel-based alloys 3 ).…”

Section: Introductionmentioning

confidence: 99%

“…1 The increasing demand of non-fusion joining techniques is moving towards the recent and promising solid-state joining technique known as friction stir welding (FSW). This is especially desired for difficult to join material combinations (such as several difficult to weld Al-alloys, 1 dissimilar alloys, 2 and varieties of steels, titanium and nickel-based alloys 3 ). Stainless steel (SS) is used in many applications, including aeronautics, locomotives, food processing industries, medical and power plants, etc.…”

Section: Introductionmentioning

confidence: 99%

Microstructural characterization and in-process traverse force during friction stir welding of austenitic stainless steel

Siddiquee

Pandey

Abidi

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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Welding AISI 304 stainless steel is challenging, especially as fusion-based welding processes (such as arc welding) severely undermine the material's corrosion resistance due to sensitization. Solid-state friction stir welding is one of the most suitable alternatives. Friction stir welding of high-strength high-softening materials such as AISI 304 is difficult mainly because of the non-availability of affordable tools and tool life. In this study, AISI 304 stainless steel was successfully butt-welded by friction stir welding. The experiments were performed using Taguchi's L27 orthogonal array. Shoulder diameter, tool r/min, and traverse speed were selected as the most influential welding parameters. A Tungsten Carbide (WC) tool was employed with a tapered pin profile. Defect-free joints were fabricated successfully for all the welding conditions. Microstructural examinations using optical microscopy and scanning electron microscopy revealed significant grain refinement in the stir zone and the presence of distinct structural features such as stepped, dual, and ditch in various characteristics zones. The presence of precipitates was also observed in samples and was confirmed via energy-dispersive X-ray spectroscopy analysis. The in-process traverse force was measured by a special arrangement of force measuring units attached to the work fixture. The traverse force data were analyzed and optimized. The results of an analysis of variance reveal that the traverse speed was the most important parameter, followed by tool r/min, interaction between the tool shoulder diameter and traverse speed, interaction between the tool shoulder diameter and tool r/min, and, finally, the tool r/min.

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“…In a not too distant future, satellites and other small objects could be produced in orbit as well as parts for Space stations or Shuttles. For this reason, some technologies have been recently studied in the optic of in‐Space manufacturing, such as friction stir welding and, mainly, 3D printing . However, many other processes have to be investigated to support production of complex parts in Space.…”

Section: Introductionmentioning

confidence: 99%

Solid‐state foaming of epoxy resin under hypergravity and simulated microgravity

et al. 2018

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Solid-state foaming of epoxy resins has been performed under simulated microgravity by the random positioning machine (RPM) and under hypergravity by the large diameter centrifuge (LDC). More than 50 tests have been performed in static and dynamic conditions in different experimental configurations. Longitudinal, radial, and volumetric foaming ratios have been extracted from foaming tests, and correlated with the applied gravity conditions. Results show that the gravity vector has two opposite effects; the first on the flow front movement and the second on the contact between the sample and the oven. The second effect seems to be stronger, and the important role of heat transfer is confirmed. Nevertheless, effects related to apply centrifugal forces have been found and discussed, above all in the case of LDC tests. K E Y W O R D Sfoams, processing, thermosets

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Development of friction stir welding technologies for in-space manufacturing

Cited by 29 publications

References 8 publications

Evaluation of Current, Force and Temperature Signals on Welding Formation of Bobbin Friction Stir Welded AA1100

Evaluation of Current, Force and Temperature Signals on Welding Formation of Bobbin Friction Stir Welded AA1100

Microstructural characterization and in-process traverse force during friction stir welding of austenitic stainless steel

Solid‐state foaming of epoxy resin under hypergravity and simulated microgravity

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