NASA NTRS1999
Friction stir welding (FSW) is a remarkable technology for making butt and lap joints in aluminum alloys. The process operates by passing a rotating tool between two closely butted plates. This process generates heat and the heated material is stirred from both sides of the plates to generate a high quality weld. Application of this technique has a very broad field for NASA. In particular, NASA is interested in using this welding process to manufacture tanks and curved elements. Therefore, this research has been oriented to the study the FSW of curved plates. The study has covered a number of topics that are important in the model development and to uncover the physical process involve in the welding itself. The materials used for the experimental welds were as close to each other as we could possibly find, aluminum 5454-0 and 5456-0 with properties listed at http://matweb.com. The application of FSW to curved plates needs to consider the behavior that we observed in this study. There is going to be larger force in the normal direction (Fz) as the curvature of the plate increases. A particular model needs to be derived for each material and thickness. A more complete study should also include parameters such as spin rate, tool velocity, and power used. The force in the direction of motion (Fx) needs to be reconsidered to make sure of its variability with respect to other parameters such as velocity, thickness, etc. It seems like the curvature does not play a role in this case. Variations in temperature were found with respect to the curvature. However, these changes seem to be smaller than the effect on Fz. The temperatures were all below the melting point. We understand now that the process of FSW produces a three dimensional flow of material that takes place during the weld. This flow needs to be study in a more detailed way to see in which directions the flow of material is stronger. It could be possible to model the flow using a 2-dimensional model in the particular directions where the flow moves faster. More experimental information is required to enrich the knowledge about FSW, and from this point, derive useful mathematical formulas to optimize the process and the design of the machines that will perform it. More experiments and experimental equipment are required to uncover the mathematics of the process.