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Temperature measurements during friction stir welding
University West, Department of Engineering Science, Division of Production System. (PTW)ORCID iD: 0000-0003-3261-9097
University West, Department of Engineering Science, Division of Production System. (PTW)ORCID iD: 0000-0001-9553-7131
University West, Department of Engineering Science, Division of Production System. (PTW)ORCID iD: 0000-0002-1869-232X
2017 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 88, no 9-12, 2899-2908 p.Article in journal (Refereed) Published
Abstract [en]

The increasing industrial demand for lighter, more complex and multi-material components supports the development of novel joining processes with increased automation and process control. Friction stir welding (FSW) is such a process and has seen a fast development in several industries.This welding technique gives the opportunity of automation and online feedback control, allowing automatic adaptation to environmental and geometrical variations of the component.Weld temperature is related to the weld quality and therefore proposed to be used for feedback control. For this purpose, accurate temperature measurements are required. This paper presents an overview of temperature measurement methods applied to the FSW process. Three methods were evaluated in this work: thermocouples embedded in the tool, thermocouples embedded in the workpiece and the tool-workpiece thermocouple(TWT) method. The results show that TWT is an accurate and fast method suitable for feedback control of FSW.

Place, publisher, year, edition, pages
Springer, 2017. Vol. 88, no 9-12, 2899-2908 p.
Keyword [en]
Friction stir welding, TWT method, temperature, aluminium, thermocouples
National Category
Manufacturing, Surface and Joining Technology
Research subject
ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-9531DOI: 10.1007/s00170-016-9007-4OAI: oai:DiVA.org:hv-9531DiVA: diva2:947429
Available from: 2016-07-08 Created: 2016-07-08 Last updated: 2017-04-19Bibliographically approved
In thesis
1. Thermo-electric temperature measurements in friction stir welding: Towards feedback control of temperature
Open this publication in new window or tab >>Thermo-electric temperature measurements in friction stir welding: Towards feedback control of temperature
2016 (English)Licentiate thesis, comprehensive summary (Other academic)
Abstract [en]

Friction Stir Welding has seen a fast uptake in many industry segments. Mechanical properties superior to fusion welding, the ability to weld "unweldable" aluminium alloys and low distortion are often described as the main reasons for the fast industrial implementation of FSW. Most existing applications consist of long straight welding joints. Applications with complex weld geometries, however, are rarely produced by FSW. These geometries can induce thermal variations during the welding process, thus making it challenging to maintain a consistent weld quality. In-process adaptation of weld parameters to respond to geometrical variations and other environmental variants allow new design opportunities for FSW. Weld quality has been shown to be reliant on the welding temperature. However, the optimal methodology to control the temperature is still under development.The research work presented in this thesis focuses on some steps to take in order to reach the improvement of the FSW temperature controller, thus reach a better and consistent weld quality. In the present work different temperature methods were evaluated. Temperature measurements acquired by the tool-workpiece thermocouple (TWT) method were accurate and fast, and thereby enhanced suitable for the controller. Different environmental conditions influencing the material heat dissipation were imposed in order to verify the controller effect on the joint quality. In comparison with no controlled weld, the use of the controller enabled a fast optimization of welding parameters for the different conditions, leading to an improvement of the mechanical properties of the joint.For short weld lengths, such as stitch welds, the initial plunge and dwell stages occupy a large part of the total process time. In this work temperature control was applied during these stages. This approach makes the plunge and dwell stages more robust by preventing local material overheating, which could lead to a tool meltdown. The TWT method was demonstrated to allow a good process control during plunging and continuous welding. The approach proposed for control offers weld quality consistency and improvement. Also, it allows a reduction of the time required for the development of optimal parameters, providing a fast adaptation to disturbances during welding and, by decreasing the plunge time, provides a significant decrease on the process time for short welds.

Place, publisher, year, edition, pages
Trollhättan: University West, 2016. 62 p.
Keyword
FSW, Robotic, Temperature, TWT, Plunge, Control
National Category
Robotics
Research subject
Production Technology
Identifiers
urn:nbn:se:hv:diva-9982 (URN)978-91-87531-43-9 (ISBN)978-91-87531-42-2 (ISBN)
Supervisors
Available from: 2016-11-09 Created: 2016-10-12 Last updated: 2016-11-10Bibliographically approved

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Silva, AnaDe Backer, JeroenBolmsjö, Gunnar
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