Heat Reduction in a Tool Holder during Friction Stir Welding of Aluminium Alloy

Abstract

Friction stir welding is a solid state welding process that uses a rotating tool to amalgamate two metals by the frictional heat generated. Recent developments in FSW of aluminium have been exploited in aerospace, marine and transport industries. The friction stir welding on aluminium metal generates heat which has detrimental effects on the system in the long run. The heat generated, due to the friction developed, has to be reduced to provide a constant thermal environment for the tool and the workpiece. This work focuses on the conception to develop a water cooled tool holder to reduce the excess temperature thereby protecting the spindle bearing. The current paper elucidates on the design and parameters of water cooled tool holder and spring loaded seal, its implementation and the results obtained by friction stir welding of aluminum.

A Review of Recent Developments in Friction Stir Welding for Various Industrial Applications

“…The shoulder is typically made from a wear-and heat-resistant material, such as tungsten carbide [41][42][43]. FSW tools often have cooling systems to dissipate the heat generated during welding, ensuring tool life and reducing the frictional forces and heat [44,45]. The pin is the smaller, threaded or profiled part of the tool that penetrates the joint.…”

“…Tool materials must have high wear resistance and withstand the mechanical and thermal stresses of the welding. Common tool materials include tungsten carbide [41,44], tool steel [66], and cermet materials. The tool material choice should be compatible with the workpiece materials to prevent contamination and facilitate proper material flow.…”