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S. K. Das et al.
Fig. 1.12 Illustration of retractable pin
1.6.3.1 Robotic Weld Tools
NASA is a pioneer in the field of FSW. It uses FSW for fabricating the cryogenic
tank for its Space Launch System (SLS) project. Apart from the conventional FSW,
NASA also makes use of self-reacting FSW which eliminates the requirement of
back plate support for the welding as well as ensuring welding throughout the plate
thickness. Robotic weld tool is being used by NASA for welding of curved gore
panels for the upper portion of the liquid hydrogen tank used on the upper stage of
NASA Constellation Ares I. The configuration used by NASA is of horizontal boring
machine (mill) type (refer Fig. 1.13).
A serial/articulate arm-based configuration is also employed by some companies
for carrying out FSW (Fig. 1.14). Their applications encompass productions ranging
from low to high volumes and variable job thickness. These types of sophisticated
configurations are mainly limited to welding moderate to lower melting point alloys.
The FSW robot technology can be used to effectively replace conventional fusion
welding and assembly line processes, viz. riveting. These systems are also equipped
to handle thin-gauged applications and weld along complex paths and curvatures.
1.6.3.2 Process/Production Development System
Various FSW setups have been used for various process/production development
systems. In fact, customized solutions for production development system are available. They are designed to handle wide range of applications varying from 2-D to
3-D thin gage to thick plate (0.75–30 mm) [71].
S. K. Das et al.
Fig. 1.12 Illustration of retractable pin
1.6.3.1 Robotic Weld Tools
NASA is a pioneer in the field of FSW. It uses FSW for fabricating the cryogenic
tank for its Space Launch System (SLS) project. Apart from the conventional FSW,
NASA also makes use of self-reacting FSW which eliminates the requirement of
back plate support for the welding as well as ensuring welding throughout the plate
thickness. Robotic weld tool is being used by NASA for welding of curved gore
panels for the upper portion of the liquid hydrogen tank used on the upper stage of
NASA Constellation Ares I. The configuration used by NASA is of horizontal boring
machine (mill) type (refer Fig. 1.13).
A serial/articulate arm-based configuration is also employed by some companies
for carrying out FSW (Fig. 1.14). Their applications encompass productions ranging
from low to high volumes and variable job thickness. These types of sophisticated
configurations are mainly limited to welding moderate to lower melting point alloys.
The FSW robot technology can be used to effectively replace conventional fusion
welding and assembly line processes, viz. riveting. These systems are also equipped
to handle thin-gauged applications and weld along complex paths and curvatures.
1.6.3.2 Process/Production Development System
Various FSW setups have been used for various process/production development
systems. In fact, customized solutions for production development system are available. They are designed to handle wide range of applications varying from 2-D to
3-D thin gage to thick plate (0.75–30 mm) [71].