28
S. K. Das et al.
1.6.3.3 Low-Cost FSW Solutions
Low-cost FSW solutions have been used for large-scale welding processes, viz.
fabrication of stiffened panels from aluminum extrusions, to be used in the construction of ships used by the US Navy [71]. The configuration of the machine used by
them was of C-Frame type with traveling workpiece. Besides, there has been effort
to enhance the monitoring capability of the existing milling machine-based setups.
LOSTIR is such a project funded by the European Commission which has led to
the development of a low-cost FSW monitoring system that can be retrofitted to
milling machines to facilitate their application to FSW [2]. This device consists of a
force monitoring system, FSW tool holder, control and logging systems and suitable
FSW tools. Currently, the system is suitable for joining low-melting point alloys,
viz. aluminum, and is able to provide fairly accurate monitoring of forces, torque
and tool temperature during friction stir welding.
1.6.3.4 Panel Production Plant
FSW equipment has been developed for the fabrication of large aluminum panels
that have various uses, viz. for shipbuilding structures and decks in marine industry,
tractor trailer flatbeds, railcar manufacture, etc. The advantage of using FSW in
this case is that it vastly reduced the reworking required to correct the warping
and distortion commonly observed in case of fusion welding. Manufacturing Technology, Inc. and ESAB AB are the companies actively involved in the development
of FSW systems suitable for panel welding. These systems can join multiple extrusions into wider panels, simultaneously perform dual sided welds on thicker panels,
join multiple single-wall extrusions to stiffeners, etc. Besides, they have large weld
capacity and can join sheets up to four feet in width and 1.5 inch in thickness.
Photograph of one of the panel production plants utilizing FSW is displayed in
Fig. 1.15.
1.7 Important Parameters in FSW
FSW provides good quality weld when executed under suitable combination of
process parameters and precise control. During welding, retreating side is the portion
through which most of the material flow occurs and the welded joint is achieved
when transportation of plasticized material occurs behind the tool. Important process
parameters that significantly affect the welded joint include traverse speed, spindle
speed, tool depth, tool tilt angle, spindle torque, forces acting on the tool (X-force,
Y-force, Z-force) during welding, etc. Variation of these parameters can affect the
S. K. Das et al.
1.6.3.3 Low-Cost FSW Solutions
Low-cost FSW solutions have been used for large-scale welding processes, viz.
fabrication of stiffened panels from aluminum extrusions, to be used in the construction of ships used by the US Navy [71]. The configuration of the machine used by
them was of C-Frame type with traveling workpiece. Besides, there has been effort
to enhance the monitoring capability of the existing milling machine-based setups.
LOSTIR is such a project funded by the European Commission which has led to
the development of a low-cost FSW monitoring system that can be retrofitted to
milling machines to facilitate their application to FSW [2]. This device consists of a
force monitoring system, FSW tool holder, control and logging systems and suitable
FSW tools. Currently, the system is suitable for joining low-melting point alloys,
viz. aluminum, and is able to provide fairly accurate monitoring of forces, torque
and tool temperature during friction stir welding.
1.6.3.4 Panel Production Plant
FSW equipment has been developed for the fabrication of large aluminum panels
that have various uses, viz. for shipbuilding structures and decks in marine industry,
tractor trailer flatbeds, railcar manufacture, etc. The advantage of using FSW in
this case is that it vastly reduced the reworking required to correct the warping
and distortion commonly observed in case of fusion welding. Manufacturing Technology, Inc. and ESAB AB are the companies actively involved in the development
of FSW systems suitable for panel welding. These systems can join multiple extrusions into wider panels, simultaneously perform dual sided welds on thicker panels,
join multiple single-wall extrusions to stiffeners, etc. Besides, they have large weld
capacity and can join sheets up to four feet in width and 1.5 inch in thickness.
Photograph of one of the panel production plants utilizing FSW is displayed in
Fig. 1.15.
1.7 Important Parameters in FSW
FSW provides good quality weld when executed under suitable combination of
process parameters and precise control. During welding, retreating side is the portion
through which most of the material flow occurs and the welded joint is achieved
when transportation of plasticized material occurs behind the tool. Important process
parameters that significantly affect the welded joint include traverse speed, spindle
speed, tool depth, tool tilt angle, spindle torque, forces acting on the tool (X-force,
Y-force, Z-force) during welding, etc. Variation of these parameters can affect the