1 Friction Stir Welding
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1.6.1.2 Using a Milling Machine—Low-Cost Setup
The issue with the dedicated setups is their higher cost, and hence, these are limited
to those industries which have sufficient funds to invest in them. Thus, technologists
have aimed to create a cost-effective solution so that the benefits of FSW process can
be reaped by industries worldwide. The configuration of the milling machine seemed
suitable for its adaptability toward the FSW process. As milling machine is a very
common machine available almost everywhere, it seemed a viable solution to tackle
the huge investment cost required to setup dedicated FSW machines. However, the
spindles in milling machines are not designed to endure the radial and thrust loads
expected during FSW process. Moreover, traditional milling machines do not offer
precise load control or load monitoring. Thus, high-quality weld is difficult to produce
through the milling machine setup. Many researchers however use this type of setup
to gain knowledge about the FSW process.
Some companies have also developed FSW units which can be retrofitted to
any conventional milling machine to convert it into a FSW setup. These type of
setups cannot be a 100% replacement for dedicated FSW setups. Nevertheless, these
converted machines can produce a decent weld quality and are simple to operate.
Figure 1.9 shows a milling machine converted to a FSW setup.
Fig. 1.9 Vertical milling machine converted to FSW setup for linear welding [67]—reprinted under
Creative Commons license
21
1.6.1.2 Using a Milling Machine—Low-Cost Setup
The issue with the dedicated setups is their higher cost, and hence, these are limited
to those industries which have sufficient funds to invest in them. Thus, technologists
have aimed to create a cost-effective solution so that the benefits of FSW process can
be reaped by industries worldwide. The configuration of the milling machine seemed
suitable for its adaptability toward the FSW process. As milling machine is a very
common machine available almost everywhere, it seemed a viable solution to tackle
the huge investment cost required to setup dedicated FSW machines. However, the
spindles in milling machines are not designed to endure the radial and thrust loads
expected during FSW process. Moreover, traditional milling machines do not offer
precise load control or load monitoring. Thus, high-quality weld is difficult to produce
through the milling machine setup. Many researchers however use this type of setup
to gain knowledge about the FSW process.
Some companies have also developed FSW units which can be retrofitted to
any conventional milling machine to convert it into a FSW setup. These type of
setups cannot be a 100% replacement for dedicated FSW setups. Nevertheless, these
converted machines can produce a decent weld quality and are simple to operate.
Figure 1.9 shows a milling machine converted to a FSW setup.
Fig. 1.9 Vertical milling machine converted to FSW setup for linear welding [67]—reprinted under
Creative Commons license