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

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

doi:10.1177/0954406212438987

Cited by 13 publications

(2 citation statements)

References 4 publications

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“…Tool wear in FSW of MMCs is an eventuality. Monitoring the amount of wear (and replacing the tool when its volume loss exceeds some critical level) represents one potential strategy for managing the wear problem (Prater et al, 2012). While this "critical level" is not defined, as (unlike machining) there are no existing standards for tool wear in FSW, it is defined for the purposes of this study as the point beyond which degradation in tool shape negatively impacts the structure of the finished joint.…”

Section: Tool Wear In Friction Stir Weldingmentioning

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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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: Tool Wear In Friction Stir Weldingmentioning

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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“…Prater et al 13 evolved a dimensionless parameter which was used to evaluate the amount of volumetric wear which an FSW tool would experience in joining an MMC. Three major process variables in the FSW process i.e., rotation speed, traverse speed, and weld length were taken into consideration for deriving a dimensionless number.…”

Section: Introductionmentioning

confidence: 99%

Comparison of tool wear during friction stir welding of Al alloy and Al-SiC metal matrix composite

Bist

Saini

Sharma³

2021

Proceedings of the Institution of Mechanical Engineers, Part E:

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Aluminum matrix composites have received considerable attention due to their high specific strength and specific stiffness, high hardness, and wear resistance along with being light in weight. These composites are preferably joined using friction stir welding process. The major concern in friction stir welding is the wear of the welding tool pin which is the backbone of the process. The wear is due to the prolonged contact between the tool and the harder reinforcements in the composite materials. The present work deals with the study of tool wear and its surface roughness with respect to different selected friction stir welding parameters such as rotational speed, transverse speed, length of weld, and different composition of Aluminum composite. It was found that the total amount of material removed from the tool and the surface roughness of the tool is in direct proportion to the rotational speed of the tool and the length of the weld but inversely proportional to the transverse rate. The increase in wt.% of SiC reinforcement leads to the higher tool wear but reduces the surface roughness of the tool.

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Characterization of Diamond-Like Carbon on WC and H13 Tool Steel to Improve the Wear Resistance of FSW Tool

Emamian,

Awang,

Meyghani

2023

Proceedings in Technology Transfer

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

Cited by 13 publications

References 4 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

Comparison of tool wear during friction stir welding of Al alloy and Al-SiC metal matrix composite

Characterization of Diamond-Like Carbon on WC and H13 Tool Steel to Improve the Wear Resistance of FSW Tool

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